Method for producing article using injection molding system

Abstract

To provide an article and a method for producing the same.SOLUTION: A method for producing an article includes the steps of: providing a molding apparatus having a first mold and a second mold, and placing a part between the first mold and the second mold, the part including a hollow space and an opening communicating with the hollow space; engaging the opening with the first mold or the second mold; mating the first mold with the second mold to form a mold cavity surrounding the part, the opening being engaged with a supply port of the molding apparatus configured to be in communication with the hollow space; injecting a molding material into the hollow space through the supply port and the opening, the molding material including a polymeric material and a foaming agent; and foaming the molding material to form a foam member. The foam member is in contact with an inner surface of the part.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] (Cross - reference to Related Applications) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 617,410, filed on January 3, 2024, and U.S. Patent Application No. 18 / 900,906, filed on September 30, 2024, the entire disclosures of which are incorporated herein by reference.

[0002] The present invention relates to an article and a method for manufacturing the same, and more particularly to an article including a foam member in contact with a component and a method for manufacturing the same.

Background Art

[0003] An article including a foam member and a component attached to at least a part of the foam member has many advantages such as high strength, low weight, and impact resistance. Since the article can be manufactured by adhering the foam member and the component, an adhesive is disposed between the foam member and the component. However, there is a need to improve the reliability of an article including a foam member and a component and a method for manufacturing the article.

Summary of the Invention

Problems to be Solved by the Invention

[0004] An object of the present invention is to provide an article and a method for manufacturing the same.

Means for Solving the Problems

[0005] According to one embodiment of the present disclosure, a method for manufacturing an article is disclosed. The method includes providing a molding apparatus having a first mold and a second mold, placing a component between the first mold and the second mold, the component including a hollow space and an opening communicating with the hollow space, engaging the opening with the first mold or the second mold, engaging the first mold with the second mold to form a mold cavity surrounding the component, the opening engaging with a supply port of the molding apparatus that can communicate with the hollow space. The method further includes injecting a molding material into the hollow space through the supply port and the opening, the molding material including a polymer material and a foaming agent, and foaming the molding material to form a foamed member. The foamed member is in contact with the inner surface of the component.

[0006] According to one embodiment of the present disclosure, a method for manufacturing an article is disclosed. The method includes providing a molding apparatus having a first mold and a second mold, placing a component between the first mold and the second mold, the component including a hollow space and an opening communicating with the hollow space, engaging the opening with the first mold or the second mold, engaging the first mold with the second mold to form a mold cavity surrounding the component, the opening engaging with a supply port of the molding apparatus that can communicate with the hollow space, the supply port being disposed on a side wall of the molding apparatus, and the component being disposed within the mold cavity. The method further includes injecting a molding material into the hollow space through the supply port and the opening, and foaming the molding material to form a foamed member. The hollow space expands within the mold cavity during the formation of the foamed member.

Brief Description of the Drawings

[0007] Aspects of the present disclosure are best understood when read in conjunction with the accompanying drawings and the following detailed description. Note that, in accordance with standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of 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 provided subject matter. To simplify the present disclosure, specific examples of components and arrangements are described below. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature above or on top of a second feature in the following description may include embodiments in which the first feature and the second feature 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 feature and the second feature do not have to be in direct contact. Further, the present disclosure may, in various embodiments, repeat reference numerals and / or letters. This repetition is for the purpose of simplification and clarity and does not in itself define 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 description to explain the relationship of one element or feature to another as shown in the drawings. Spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation shown in the drawings. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations), and the spatially relative descriptors used herein may be interpreted accordingly.

[0011] Numerical ranges and parameters which represent the broad scope of the present disclosure are approximations, and although the numerical values set forth in the specific examples are reported as accurately as possible, any numerical value inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. 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 the mean allowable standard error as considered by one of ordinary skill in the art. Except in the case of operating / working examples, or where otherwise expressly indicated, all numerical ranges, amounts, values and percentages disclosed herein, for example, those for amounts of materials, durations of time, temperatures, operating conditions, ratios of amounts, etc., 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 specified.

[0012] FIG. 1 is a schematic view of an injection molding system 200 according to an embodiment of the present invention. The injection molding system 200 includes an extrusion system 110 and a molding apparatus 100, as shown in FIG. 1. The extrusion system 110 is configured to produce a molding material of a polymer material and a foaming agent. In some embodiments, the molding material is foamable or slightly foamable.

[0013] In some embodiments, the polymeric material includes a high molecular weight polymer. In some embodiments, the polymeric material includes ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), and the like. In some embodiments, the polymeric material includes a foaming material. In some embodiments, the foaming agent is a physical or chemical additive that releases a gas, thereby forming pores in the resulting foamed polymer article. In some embodiments, the foaming agent is a physical foaming agent. Physical foaming agents include atmospheric gases (e.g., nitrogen or carbon dioxide), hydrocarbons, chlorofluorocarbons, noble gases, or combinations thereof. The foaming agent may be supplied in any fluid physical state, such as a gas, a liquid, or a supercritical fluid (SCF).

[0014] FIG. 2 is a schematic view of an extrusion system 110 according to aspects of the present disclosure in some embodiments. The extrusion system 110 includes a melting unit 120, a mixing unit 130, a foaming agent supply unit 140, and an injection unit 150. In some embodiments, the extrusion system 110 further includes a first flow control element 161, a second flow control element 162, and a monitoring module 180.

[0015] In some embodiments, referring to FIG. 2, the melting unit 120 is configured to convey a polymeric material. The melting unit 120 includes a pressing cartridge 121, a first supply passage 122, a first discharge passage 123, and a pushing member 124. In some embodiments, the melting unit 120 further includes a supply hopper 125.

[0016] In some embodiments, the first supply passage 122 and the first discharge passage 123 are respectively disposed at both ends of the pressing cartridge 121. In some embodiments, the first supply passage 122 communicates with the internal space 1211 of the pressing cartridge 121, the first discharge passage 123 communicates with the external space of the pressing cartridge 121, and the first supply passage 122 is configured to deliver a polymer material to the internal space 1211 of the pressing cartridge 121. In some embodiments, the supply hopper 125 is configured to deliver a polymer material to the internal space 1211 of the pressing cartridge 121 through the first supply passage 122.

[0017] The pushing member 124 is configured to convey the polymer material from the first supply passage 122 to the first discharge passage 123. In some embodiments, the pushing member 124 is disposed in the internal space 1211 of the pressing cartridge 121. In some embodiments, the pushing member 124 is disposed in the internal space 1211 of the pressing cartridge 121 between the first supply passage 122 and the first discharge passage 123 and is used to urge the polymer material toward the first discharge passage 123. In some embodiments, the pushing member 124 is rotatable relative to the pressing cartridge 121. In some embodiments, the polymer material is conveyed from the first supply passage 122 to the first discharge passage 123 by the rotation of the pushing member 124. In some embodiments, the pushing member 124 cannot move in a direction parallel to the longitudinal axis of the pressing cartridge 121.

[0018] In some embodiments, the length of the pushing member 124 extends along the length of the pressing cartridge 121, and the ratio of the distance D1 between the inner sidewall 1212 of the pressing cartridge 121 and the pushing member 124 to the diameter D2 of the pushing member 124 is in the range of about 1:1500 to about 1:4500, and the polymeric material melted by the melting unit 120 is homogenized. In some embodiments, the shortest distance D1 between the inner sidewall 1212 of the pressing cartridge 121 and the pushing member 124 is substantially 0.3 mm or less. In some embodiments, the shortest distance D1 between the inner sidewall 1212 of the pressing cartridge 121 and the pushing member 124 is in the range of 0.01 to 0.05 mm.

[0019] The mixing unit 130 is configured to receive the polymeric material from the melting unit 120, mix the polymeric material with the blowing agent, and form a molding material of the polymeric material and the blowing agent. The mixing unit 130 includes a hollow mixing cartridge 131, a second supply passage 132, a second discharge passage 133, and a mixing rotor 134.

[0020] The second supply passage 132 and the second discharge passage 133 are respectively disposed at both ends of the mixing cartridge 131. In some embodiments, the second supply passage 132 is configured to deliver the polymeric material. In some embodiments, the second discharge passage 133 is configured to discharge the molding material.

[0021] The mixing rotor 134 is configured to mix a polymer material with a foaming agent to form a molding material within the mixing cartridge 131. In some embodiments, the mixing rotor 134 is disposed within the mixing cartridge 131. In some embodiments, the mixing rotor 134 is disposed within the mixing cartridge 131 between the second supply passage 132 and the second discharge passage 133 so as to stir the molding material within the mixing cartridge. The mixing rotor 134 is rotatable to mix the polymer material and the foaming agent and convey the molding material of the polymer material and the foaming agent from the second supply passage 132 to the second discharge passage 133. In some embodiments, the mixing rotor 134 cannot move in a direction parallel to the longitudinal axis of the mixing cartridge 131.

[0022] In some embodiments, the length of the mixing rotor 134 extends along the length of the hollow mixing cartridge 131, and the ratio of the shortest distance D3 between the inner side wall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 to the diameter D4 of the mixing rotor 134 is in the range of about 1:1500 to about 1:4500, and the molding material prepared by the extrusion system 110 may be uniform and homogenized. In some embodiments, the molding material may be divided into a plurality of parts, and the ratio of the polymer material to the foaming agent of each part of the molding material prepared by the extrusion system 110 is substantially constant. In some embodiments, the ratio of the polymer material to the foaming agent in the first part of the molding material is substantially equal to the ratio of the polymer material to the foaming agent in the second part of the molding material. In some embodiments, the shortest distance D3 between the inner side wall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 is substantially 0.3 mm or less. In some embodiments, the shortest distance D3 between the inner side wall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 is in the range of 0.01 to 0.09 mm.

[0023] Figure 2A is an enlarged view of a portion of an extrusion system according to aspects of the present disclosure in some embodiments. Referring to FIGS. 2 and 2A, in some embodiments, to uniformly mix the molten polymer material and the foaming agent within the mixing cartridge 131, the mixing rotor 134 further includes a cylindrical columnar body 1341 rotatably disposed within the mixing cartridge 131 and a groove portion 1342 annularly disposed around the columnar body 1341. Thus, when the columnar body 1341 rotates, the polymer material and the foaming agent are agitated by the groove portion 1342 to obtain a desired mixing effect. In some embodiments, the shortest distance D3 is the shortest distance between the groove portion 1342 and the inner side wall 1311 of the hollow mixing cartridge 131. In some embodiments, when the shortest distance D3 is the shortest distance between the groove portion 1342 and the inner side wall 1311 of the hollow mixing cartridge 131, the shortest distance D3 ranges from 0.01 to 0.09 mm. In some embodiments, the diameter D4 of the mixing rotor 134 ranges from 45 to 75 mm.

[0024] In some embodiments, when the shortest distance D3 is less than substantially 0.01 mm, the foaming agent in a predetermined amount of molding material is substantially over 0.8 / cm 3 In some embodiments, when the foaming agent in a predetermined amount of molding material substantially exceeds 0.8 / cm 3 the bubble density in a predetermined amount of molding material after foaming is substantially over 180,000 / cm 3

[0025] In some embodiments, when the ratio of the shortest distance D3 to the diameter D4 is in the range of 1:1500 to 1:4500, the uniformity of the foaming agent with respect to the polymer material is optimized. In other words, the mixing of the foaming agent and the polymer material by the mixing rotor 134 is uniform and homogenized. In some embodiments, when the ratio of the shortest distance D3 to the diameter D4 is in the range of 1:1500 to 1:4500, the ratio of the foaming agent to the polymer material in a predetermined amount of the molding material is in the range of 4:1 to 3:1. In some embodiments, the ratio of the foaming agent to the polymer material in a predetermined amount of the molding material is about 1:1. In some embodiments, when the ratio of the foaming agent to the polymer material in a predetermined amount of the molding material is in the range of 4:1 to 3:1, the ratio of the bubbles to the polymer material in a predetermined amount of the molding material after foaming is also in the range of 4:1 to 3:1. In some embodiments, the ratio of the bubbles to the polymer material in a predetermined amount of the molding material after foaming is in the range of about 4:1.

[0026] In some embodiments, the melting unit 120 is configured to contain a polymer material and includes a hollow pressing cartridge 121 having a first pressure, and the mixing unit 130 includes a hollow mixing cartridge 131 having a second pressure. In some embodiments, in order to prevent backflow, the first pressure is greater than the second pressure. In some embodiments, the polymer material is drawn from the melting unit 120 towards the mixing unit 130 by the difference between the first pressure and the second pressure.

[0027] The foaming agent supply unit 140 is connected to the mixing unit 130 and conveys the foaming agent to the mixing unit 130. In some embodiments, the foaming agent supply unit 140 is disposed between the first flow control element 161 and the second flow control element 162. In some embodiments, the foaming agent supply unit 140 is disposed proximal to the first flow control element 161 and distal to the second flow control element 162.

[0028] In some embodiments, a blowing agent source (not shown) is connected to the blowing agent supply unit 140 and configured to supply any type of blowing agent known to those skilled in the art. In some embodiments, the blowing agent is in a supercritical fluid state after being introduced into the mixing unit 130 by the blowing agent supply unit 140.

[0029] In some embodiments, the first flow control element 161 is disposed at a first port 171 that connects the melting unit 120 to the mixing unit 130. The first port 171 is configured to introduce the polymer material from the melting unit 120 into the mixing unit 130. The first port 171 is located between the melting unit 120 and the mixing unit 130. In some embodiments, the first port 171 is configured to introduce the polymer material from the pressing cartridge 121 of the melting unit 120 into the mixing cartridge 131 of the mixing unit 130. In some embodiments, the polymer material can be conveyed and / or drawn from the melting unit 120 through the first port 171 into the mixing unit 130 by a pressure difference between a first pressure and a second pressure.

[0030] In some embodiments, the first flow control element 161 is disposed between the melting unit 120 and the mixing unit 130 and configured to control the flow of the polymer material from the melting unit 120 to the mixing unit 130. The first flow control element 161 may be a valve, a movable cover, or the like.

[0031] In some embodiments, the first flow control element 161 is configured to switch between an open configuration and a closed configuration. The open configuration of the first flow control element 161 allows the polymer material to flow from the melting unit 120 into the mixing unit 130, and the closed configuration of the first flow control element 161 prevents the polymer material from flowing back from the mixing unit 130 into the melting unit 120.

[0032] In some embodiments, the first flow control element 161 is configured to maintain a pressure difference between the melting unit 120 and the mixing unit 130. In some embodiments, the first flow control element 161 is configured to maintain the pressure difference between the melting unit 120 and the mixing unit 130 by switching between an open configuration and a closed configuration so that the polymer material cannot flow backward from the mixing cartridge 131 of the mixing unit 130 to the pressing cartridge 121 of the melting unit 120. In some embodiments, the first flow control element 161 is configured to adjust the first pressure and / or the second pressure to maintain the pressure difference between the first pressure and the second pressure. In some embodiments, when the first pressure is the same as the second pressure, the first flow control element 161 is in a closed configuration.

[0033] In some embodiments, the injection unit 150 is configured to receive the molding material discharged from the second discharge passage 133 of the mixing unit 130 and discharge the molding material from the injection unit 150. In some embodiments, the injection unit 150 is configured to inject the molding material, and the discharge channel 111 is in communication with the injection unit 150.

[0034] In some embodiments, the injection unit 150 includes a hollow metering cartridge 151 configured to contain the molding material. The metering cartridge 151 has a hollow internal space 1511, and the internal space 1511 communicates with the second discharge passage 133 and is configured to contain the molding material. The injection unit 150 further includes a connection passage 152 communicating with the internal space 1511 of the metering cartridge 151 and a discharge member 153 slidably disposed in the internal space 1511 of the metering cartridge 151 and configured to discharge the molding material from the metering cartridge 151 through an outlet 154.

[0035] Referring again to FIG. 1, in some embodiments, the injection unit 150 is configured to discharge the molding material into the molding device 100 through a discharge channel 111 corresponding to one extrusion system 110. In some embodiments, the discharge channel 111 in communication with the injection unit 150 is engageable with the molding device 100 and is configured to discharge the molding material into the mold cavity 103 of the molding device 100. The molding material flows from the extrusion system 110 into the discharge channel 111.

[0036] In some embodiments, the discharge channel 111 has an outlet 111o remote from the injection unit 150. The discharge channel 111 can be moved, extended, or retracted from the molding device 100. In some embodiments, the outlet 111o of the discharge channel 111 may extend into and retract from the molding device 111. The molding device 100 includes a mold cavity 103 and a supply port 104 that is in communication with the mold cavity 103 and is correspondingly engageable with the outlet 111o.

[0037] In some embodiments, the molding device 100 includes a first mold 101 and a second mold 102. The first mold 101 is engageable with the second mold 102. The molding device 100 is in a closed configuration when the first mold 101 engages the second mold 102. In some embodiments, the first mold 101 is a lower mold, the second mold 102 is an upper mold, and the first mold 101 is below the second mold 102. In some embodiments, when the first mold 101 engages the second mold 102, the mold cavity 103 of the molding device 100 is defined by the first mold 101 and the second mold 102. The mold cavity 103 is configured to hold the molding material or a foam member formed from the molding material.

[0038] In some embodiments, the supply port 104 is engageable with the outlet 111o. The supply port 104 is provided on the first mold 101 or the second mold 102. In some embodiments, as shown in FIG. 1, the supply port 104 is disposed on the side surface of the molding apparatus 100. In some embodiments, the supply port 104 is disposed on the first side wall 101s of the first mold 101 or the second side wall 102s of the second mold 102. The supply port 104 is configured to receive molding material from the discharge channel 111 of the injection unit 150 when the discharge channel 111 engages with the molding apparatus 100. The molding material can flow into the mold cavity 103 through the supply port 104. In some embodiments, the supply port 104 enables the molding material to flow at a predetermined flow rate.

[0039] In some embodiments, the injection molding system 200 includes a support device 114 configured to fix the discharge channel 111 to the molding apparatus 100. In some embodiments, the support device 114 includes a first element 1141 and a second element 1142. In some embodiments, the first element 1141 protrudes from the extrusion system 110, and the second element 1142 is disposed on the molding apparatus 100.

[0040] The molding apparatus 100 further includes one or more pressure adjustment systems 106. In some embodiments, the molding apparatus 100 may include a different number of pressure adjustment systems 106 or may not include a pressure adjustment system 106. In some embodiments, the junction point 107 is connected to the mold cavity 103. In some embodiments, the interior sidewall 105a or the interior bottom wall 105b of the mold cavity 103 includes the junction point 107. In some embodiments, the junction point 107 is configured to enable fluid or gas to enter or exit the mold cavity 103.

[0041] The pressure regulation system 106 may include a first gas conduit 1061, a second gas conduit 1062, a gas source 1063, a first valve 1064, a second valve 1065, and a pressure sensing unit 1066. In some embodiments, one end of the first gas conduit 1061 is coupled to the inner sidewall 105a or the inner bottom wall 105b of the molding device 100. In some embodiments, one end of the first gas conduit 1061 is coupled to the joint point 107, and the other end of the first gas conduit 1061 is coupled to the gas source 1063. In some embodiments, the gas source 1063 is configured to supply a fluid or a gas, and may supply an appropriate fluid or gas as needed. For example, the fluid or gas may be air, an inert gas, etc., but the present invention is not limited thereto.

[0042] The position, shape, and number of the joint point 107 are not particularly limited and may be adjusted as needed. In some embodiments, the joint point 107 is a hole. In some embodiments, the joint point 107 is disposed on the inner sidewall 105a or the inner bottom wall 105b of the molding device 100 and penetrates the first mold 101. In some embodiments, the joint point 107 is configured to supply gas and discharge gas. When the first valve 1064 is opened and the second valve 1065 is closed, a fluid or gas is supplied to the mold cavity 103. When the first valve 1064 is closed and the second valve 1065 is opened, at least a portion of the fluid or gas in the mold cavity 103 is discharged.

[0043] In some embodiments, the supply port 104 is disposed on the inner sidewall 105a of the molding device 100. In some embodiments, the supply port 104 and the joint point 107 are disposed on opposite sides of the mold cavity 103. By way of example and not limitation, the supply port 104 is disposed on one side of the inner sidewall 105a, and the joint point 107 is disposed on the opposite side of the inner sidewall 105a. In some embodiments, the supply port 104 is separated from the joint point 107.

[0044] The first valve 1064 is disposed in the first gas conduit 1061 and is configured to control whether gas from the gas source 1063 enters the mold cavity 103 through the first gas conduit 1061 and the junction 107. The second gas conduit 1062 is coupled to the mold and communicates with the mold cavity 103. In some embodiments, the second gas conduit 1062 is coupled to the junction 107. The second valve 1065 is disposed in the second gas conduit 1062 and is configured to control whether gas from the mold cavity 103 is discharged through the second gas conduit 1062 via the junction 107.

[0045] In some embodiments, the second gas conduit 1062 is coupled to the first gas conduit 1061 and the junction 107. In some embodiments, one end of the second gas conduit 1062 communicates with a space having a pressure lower than the pressure in the mold cavity 103, such as the external environment or a negative pressure space, but the present invention is not limited thereto. The position where the second gas conduit 1062 connects to the first gas conduit 1061 is not particularly limited. For example, it may be connected at one end adjacent to the end of the first gas conduit 1061 that connects to the junction 107. In some embodiments, the first valve 1064 and the second valve 1065 are not opened simultaneously.

[0046] The pressure sensing unit 1066 is configured to sense the pressure in the mold cavity 103. In some embodiments, the properties of the foamed polymer are affected by the pore size and distribution across the polymer, but the pore size and distribution are related to temperature, pressure, and feed rate. The pressure sensing unit 1066 is not particularly limited as long as it can sense the pressure in the mold cavity 103 and provide pressure information after sensing the pressure. The pressure adjustment system 106 changes the conditions for gas to enter and exit the mold cavity 103 according to the pressure information in order to adjust the pressure in the mold cavity 103 so that the resulting foamed polymer article has the desired predetermined shape and properties.

[0047] In some embodiments, the pressure sensing unit 1066 is disposed within the mold cavity 103, the first gas conduit 1061, or the second gas conduit 1062. In some embodiments, the pressure sensing unit 1066 is disposed within the mold cavity 103 and is away from the supply port 104. In some embodiments, the pressure regulation system 106 includes a plurality of pressure sensing units 1066. The number and positions of the plurality of pressure sensing units 1066 are not particularly limited, and for example, they can be disposed on the inner sidewalls of the mold cavity 103, spaced apart from each other, and / or disposed at any location of the first gas conduit 1061, and / or disposed at any location of the second gas conduit 1062, but the present invention is not limited thereto.

[0048] In some embodiments, the injection molding system 200 further includes a control system 109. The control system 109 is configured to control the extrusion system 110, the discharge channel 111, and the molding device 100. In some embodiments, the control system 109 automatically controls the extrusion system 110, the discharge channel 111, and the molding device 100 in real time. In some embodiments, the control system 109 controls the pressure regulation system 106 in real time.

[0049] In some embodiments, the control system 109 includes a central processor 1091 and a plurality of sensors 1092 electrically connected to or communicable with the central processor 1091. In some embodiments, the sensors 1092 are arranged throughout the injection molding system 200 and are configured to sense at least one processing condition (e.g., the flow rate or viscosity of the molding material through the discharge channel 20, the amount of molding material discharged from the discharge channel 111, the pressure within the mold cavity 103, etc.) at a predetermined position of the injection molding system 200 (e.g., the extrusion sequence to the molding device 100, the alignment of the discharge channel 111 with the molding device 100, the outlet 111o, the supply port 104, the mold cavity 103, etc.). In some embodiments, the sensors 1092 are configured to detect the processing condition and transmit a signal or data based on the detected processing condition to the central processor 1091 for further analysis.

[0050] In some embodiments, the control system 109 controls which molding device 100 the discharge channel 111 docks with. In some embodiments, a cable 1093 is electrically connected between the control system 109 and the extrusion system 110, the discharge channel 111, and the molding device 100. The cable 1093 is configured to transmit signals from the molding device 100 to the extrusion system 110 and the discharge channel 111.

[0051] In some embodiments, the control system 109 is configured to process the pressure information detected by the pressure sensing unit 1066 and to adjust the mixing conditions of the extrusion system 110 and the extrusion amount and timing of the discharge channel 111. In some embodiments, the pressure sensing unit 1066 provides the pressure information to the control system 109, and the control system 109 adjusts the first valve 1064 and the second valve 1065 according to the pressure information. In some embodiments, the control system 109 adjusts, in real time, the conditions for the gas to enter / exit the mold cavity 103 according to the pressure information, and adjusts the timing and amount of the molding material injected from the discharge channel 111 into the mold cavity 103 so that the amount and speed of injection are appropriate or within a predetermined range during the injection molding process, so that the pressure within the mold cavity 103 is always within an appropriate or predetermined pressure range. In some embodiments, the control system 109 further controls the supply conditions of the supply port 104 and the gas supply conditions of the gas source 1063. In some embodiments, the control system 109, the first valve 1064, the second valve 1065, the pressure sensing unit 1066, and the supply port 104 are electrically connected.

[0052] FIG. 3 is a schematic diagram of an injection molding system 300 according to an embodiment of the present invention. As shown in FIG. 3, the injection molding system 300 includes an extrusion system 110 having an injection unit 150 and a molding device 100. In some embodiments, the supply port 104 is disposed between the first mold 101 and the second mold 102. In some embodiments, the supply port 104 includes a first partial port 104a in the first mold 101 and a second partial port 104b in the second mold 102, and the first partial port 104a is aligned with the second partial port 104b when the molding device 100 is in a closed configuration. In some embodiments, the first partial port 104a is configured as a recess in the first side wall 101s of the first mold 101, and the second partial port 104b is configured as a recess in the second side wall 102s of the second mold 102.

[0053] In the present disclosure, a method of manufacturing an article is disclosed. In some embodiments, injection molding is performed by the method. The method includes several operations, and the description and illustration are not considered to limit the sequence of operations. FIG. 4 is a flowchart showing an injection molding method according to an embodiment of the present invention. In some embodiments, as shown in FIG. 4, the method of manufacturing the article 119 shown in FIGS. 16 and 17 includes the following steps.

[0054] Step 401 includes providing a molding device having a first mold and a second mold. Step 402 includes placing a part between the first mold and the second mold, the part including a hollow space and an opening communicating with the hollow space. Step 403 includes engaging the opening with the first mold or the second mold. Step 404 includes engaging the first mold with the second mold to form a mold cavity surrounding the part, and the opening engages with a supply port of the molding device that can communicate with the hollow space.

[0055] Step 405 includes injecting a molding material into the hollow space through the supply port and the opening, the molding material including a polymer material and a foaming agent. Step 406 includes foaming the molding material to form a foamed member. In some embodiments, the supply port is disposed on a side wall of the molding device. In some embodiments, the foamed member is in contact with the inner surface 112c of the part. In some embodiments, the hollow space expands within the mold cavity during the formation of the foamed member.

[0056] Method 400 is not limited to the above-described embodiments. In some embodiments, the method of manufacturing the article 119 shown in FIGS. 16 and 17 uses any of the above-described injection molding systems 200, 300 as shown in FIGS. 1 to 3.

[0057] FIGS. 5A and 5B are flowcharts showing an injection molding method according to an embodiment of the present invention. In some embodiments, as shown in FIGS. 5A and 5B, the method 500 of manufacturing an article includes the following steps.

[0058] According to some embodiments of the present disclosure, a method of manufacturing an article is disclosed. In some embodiments, the above-described injection molding systems 200 and 300 as shown in FIGS. 1-3 are used by method 500. FIGS. 5A and 5B are flowcharts of method 500 according to some embodiments. Method 500 includes a number of operations (501-512), and the description and illustration are not considered to limit the sequence of operations. Additional steps can be provided before, between, and after the operations shown in FIGS. 5A and 5B, and in other embodiments of method 500, some of the operations described below can be replaced or omitted. The order of operations can be interchangeable.

[0059] FIGS. 6-8 and FIGS. 11-15 are schematic cross-sectional views of one or more operations of method 500 for manufacturing an article according to some embodiments of the present disclosure. FIG. 10 is a schematic view of a portion of an injection molding system according to an embodiment of the present disclosure. FIGS. 16 and 17 are schematic cross-sectional views showing an article 119 manufactured by method 500 according to some embodiments of the present disclosure. Method 500 begins with operation 501. Operation 501 includes providing an extrusion system 110 having a melting unit 120 and a mixing unit 130 as shown in FIG. 2 and configured to generate a molding material 113' as shown in FIG. 12. Method 500 proceeds to operation 502. Operation 502 includes providing a discharge channel 111 that is in communication with the extrusion system 110, is disposed distal to the extrusion system 110, and includes an outlet 111o configured to discharge the molding material 113'.

[0060] Method 500 proceeds to operation 503. Operation 503 includes providing a molding apparatus 100 having a first mold 101 and a second mold 102. In some embodiments, operation 503 of method 500 is similar to operation 401 of method 400.

[0061] In some embodiments, referring to FIG. 6, the molding device 100 includes a second mold 102 and a first mold 101 on the opposite side of the second mold 102. In some embodiments, the second mold 102 is the upper mold and the first mold 101 is the lower mold. In some embodiments, the second mold 102 and the first mold 101 are separated from each other. In some embodiments, the second mold 102 and the first mold 101 may be aligned and complementarily positioned with each other and separable from each other. In some embodiments, the first mold 101 or the second mold 102 includes a supply port 104. In some embodiments, the supply port 104 is disposed on the first side wall 101s of the first mold 101 or the second side wall 102s of the second mold 102.

[0062] The method 500 proceeds to operations 504 and 505. Operation 504 includes placing a component 112 between the first mold 101 and the second mold 102, and the component 112 has a hollow space 112a and an opening 112b communicating with the hollow space 112a. Operation 505 includes engaging the opening 112b with the first mold 101 or the second mold 102. In some embodiments, operations 504 and 505 of method 500 are similar to operations 402 and 403 of method 400.

[0063] Referring to FIG. 7, the component 112 is disposed in the first mold 101 or the second mold 102. In some embodiments, the component 112 is disposed in the first partial mold cavity 103a of the first mold 101 and is at least partially in contact with the first mold 101. In some embodiments, the component 112 is in contact with one or more of the inner side walls 105a of the first mold 101. In some embodiments, the second mold 102 has a second partial mold cavity 103b corresponding to the first partial mold cavity 103a.

[0064] In some embodiments, the component 112 is flexible, elastic, or resilient. In some embodiments, the component 112 is a cloth, fabric, textile, etc. In some embodiments, the component 112 has breathability.

[0065] Method 500 proceeds to operation 506. Operation 506 includes engaging the first mold 101 with the second mold 102 to form a mold cavity 103 that surrounds the part 112, and the opening 112b engages with the supply port 104 of the molding device 100 that can communicate with the hollow space 112a. In some embodiments, operation 506 of method 500 is similar to operation 404 of method 400. In some embodiments, the supply port 104 is disposed on the inner sidewall 105a of the molding device 100.

[0066] In some embodiments, referring to FIG. 8, when the second mold 102 and the first mold 101 are aligned and positioned complementarily with each other, the mold cavity 103 is defined. The mold cavity 103 may be defined by the first mold cavity 103a of the first mold 101 and the second mold cavity 103b of the second mold 102. In some embodiments, the inner sidewall 105a of the molding device 100 is curved. In some embodiments, the inner sidewall 105a of the molding device 100 is a curved surface including a concave surface, a convex surface, or a combination of a concave surface and a convex surface. In some embodiments, the opening 112b and the portion of the part 112 adjacent to the opening 112b are disposed within the supply port 104 when the opening 112b engages with the supply port 104, and the portion of the part 112 is inserted into the supply port 104. The part 112 is disposed in the first mold 101 and / or the second mold 102 when the opening 112b engages with the supply port 104. As a result, the supply port 104 can communicate with the hollow space 112a when the opening 112b engages with the supply port 104.

[0067] After placing the component 112 in the first mold 101 or the second mold 102, as shown in FIG. 8, the first mold 101 is engaged with the second mold 102. The molding apparatus 100 is in a closed configuration when the first mold 101 is engaged with the second mold 102. The first partial mold cavity 103a and the second partial mold cavity 103b combine to form the mold cavity 103 when the first mold 101 is engaged with the second mold 102. The component 112 is encapsulated within the mold cavity 103 by the molding apparatus 100.

[0068] The method 500 proceeds to operation 507. Operation 507 includes engaging the discharge channel 111 with the supply port 104 before or after engaging the first mold 101 and the second mold 102.

[0069] Returning to FIG. 7, the extrusion system 110 and the discharge channel 111 are away from the molding apparatus 100. In some embodiments, the discharge channel 111 is moved to a first position adjacent to the molding apparatus 100 before engaging the outlet 111o with the supply port 104 of the molding apparatus 100. In some embodiments, the discharge channel 111 is moved to a first position adjacent to the molding apparatus 100. At the first position, the discharge channel 111 is aligned with the supply port 104 of the molding apparatus 100. In some embodiments, the distance between the outlet 111o and the supply port 104 is greater than zero. In some embodiments, at the first position, the discharge channel 111 is aligned with the supply port 104.

[0070] In some embodiments, referring to FIG. 8, after the discharge channel 111 is aligned with the supply port 104, the discharge channel 111 is moved toward the molding apparatus 100 to be received by the supply port 104, and then the outlet 111o is docked with the supply port 104. In some embodiments, the discharge channel 111 is moved toward the molding apparatus 100 to be received by the supply port 104. In some embodiments, the discharge channel 111 is moved toward the molding apparatus 100 to be received by the supply port 104.

[0071] In some embodiments, before or after engaging the first mold 101 and the second mold 102, the discharge channel 111 is engaged with the supply port 104. After the outlet 111o is docked to the supply port 104, the outlet 111o and the supply port 104 form a flow path for the molding material 113’, and as a result, the discharge channel 111 communicates with the hollow space 112a through the discharge port 104 and the opening 112b. In some embodiments, the discharge channel 111 partially protrudes into the supply port 104 when the discharge channel 111 is engaged with the supply port 104. In some embodiments, the opening 112b and the portion of the component 112 adjacent to the opening 112b are disposed within the supply port 104 when the opening 112b is engaged with the supply port 104.

[0072] The outlet 111o must be firmly engaged with the supply port 104 to prevent the molding material 113’ from leaking out of the molding apparatus 100. In some embodiments, the method 500 includes fixing the discharge channel 111 to the molding apparatus 100. In some embodiments, a force is provided by the support device 114 to prevent the extrusion system 110 from separating from the molding apparatus 100.

[0073] In some embodiments, when the extrusion system 110 injects the molding material 113’ into the molding apparatus 100, the molding apparatus 100 may generate a reaction force opposite to the injection direction, and this reaction force may be transmitted to the discharge channel 111 and the extrusion system 110. As a result, the discharge channel 111 tends to separate from the molding apparatus 100. In some embodiments, the support device 114 provides support against the reaction force opposite to the injection direction.

[0074] In some embodiments, the discharge channel 111 is fixed to the molding device 100 by engaging the first element 1141 of the support device 114 with the second element 1142 of the support device 114 to form the discharge channel 111. The first element 1141 protrudes from the extrusion system 110, and the second element 1142 is disposed on the molding device 100. In some embodiments, a force is provided by the support device 114 after engagement to prevent the discharge channel 111 from separating from the molding device 100.

[0075] FIG. 9 is a schematic view of a portion of an injection molding system 200 according to an embodiment of the present disclosure. In some embodiments, referring to FIG. 9, the support device 114 includes a first element 1141 and a second element 1142 configured to engage with each other. The first element 1141 protrudes from the extrusion system 110 or the discharge channel 111, and the second element 1142 is disposed on the molding device 100, but the present disclosure is not limited thereto. In some embodiments, the first element 1141 and the second element 1142 can be clamped together. For example, the second element 1142 is configured to receive the first element 1141.

[0076] In some embodiments, the support device 114 is disposed adjacent to the mold cavity 103 of the molding device 100. In some embodiments, the first element 1141 is disposed on the discharge channel 111, and the second element 1142 is disposed on the molding device 100. In some embodiments, the first element 1141 is a part of the extrusion system 110 or the discharge channel 111, and the second element 1142 is a part of the molding device 100. In some embodiments, the first element 1141 is a part of the extrusion system 110 and is disposed adjacent to the discharge channel 111. In some embodiments, the first element 1141 and the second element 1142 engage with each other, whereby the discharge channel 111 can be firmly engaged with the molding device 100.

[0077] In some embodiments, to prevent the extrusion system 110 from separating from the molding device 100 during injection, the engaged first element 1141 receives a force that resists the second element 1142. That force may be equal to or greater than a threshold value. The threshold value may be adjusted according to the pressure in the mold cavity 103 and the hollow space 112a and the diameter of the outlet 111o, or may be adjusted according to other factors.

[0078] The position and number of the first elements 1141 may be adjusted as needed and are not particularly limited. The position and number of the second elements 1142 may also be adjusted as needed and are not particularly limited. In some embodiments, the position and number of the second elements 1142 correspond to the position and number of the first elements 1141. In one embodiment, the first element 1141 can be disposed at any suitable position on or adjacent to the discharge channel 111, and the second element 1142 can be disposed at any suitable position on the molding device 100.

[0079] FIG. 10 is a schematic view of a portion of an injection molding system 200 according to an embodiment of the present invention. In some embodiments, referring to FIG. 10, the support device 114 can be in either of two states: a locked state and an unlocked state. In the unlocked state, the first element 1141 enters the corresponding second element 1142 but is not yet locked to the second element 1142. In other words, the first element 1141 can still be pulled out of the second element 1142 when the support device 114 is in the unlocked state. In the locked state, the first element 1141 enters and locks with the corresponding second element 1142 so that the first element 1141 cannot be pulled out of the second element 1142. FIG. 10 shows the support device 114 in the locked state. The support device 114 can be operated and controlled manually or automatically. The support device 114 can be switched manually or automatically between the two states.

[0080] In some embodiments, the first element 1141 is rotatably fixed to the extrusion system 110. In some embodiments, the first element 1141 includes a long portion 1143 and an arm portion 1144. The long portion 1143 and the arm portion 1144 are rotatable in the direction of arrow A. The long portion 1143 is fixed to the extrusion system 110 and extends in a first direction Z toward the second mold 102. The arm portion 1144 is connected to the long portion 1143 and extends in a second direction X that is substantially orthogonal to the first direction Z or in a third direction Y that is substantially orthogonal to the first direction Z. In some embodiments, the first element 1141 has an inverted T shape. After the first element 1141 enters the second element 1142, the support device 114 changes from an unlocked state to a locked state by rotation of the arm portion 1144 of the first element 1141. In some embodiments, the first element 1141 is locked with the second element 1142 by rotating the arm portion 1144 of the first element 1141 by about 90 degrees. FIG. 10 shows that the arm portion 1144 is locked with the second element 1142 after the arm portion 1144 has rotated by about 90 degrees. As a result, the support device 114 is in a locked state, the discharge channel 111 is firmly engaged with the molding device 100, and thus, the injection of the molding material 113' from the extrusion system 110 and the discharge channel 111 into the molding device 100 can be started.

[0081] In some embodiments, referring to FIGS. 8 - 10, the discharge channel 111 is fixed to the molding apparatus 100 by rotating the support device 114 in a locked state, such as by engaging the outlet 111o with the supply port 114 while rotating the first element 1141 of the support device 114 relative to and within the second element 1142 of the support device 114. In some embodiments, when the outlet 111o is docked with the supply port 114, the first element 1141 enters the second element 1142 and is then locked with the second element 1142. In some embodiments, the discharge channel 111 is fixed to the molding apparatus 100 by rotating the elongate portion 1143 and the arm portion 1144 of the first element 1141 of the support device 114, the elongate portion 1143 being fixed to the extrusion system 110 and extending in a first direction Z towards the molding apparatus 100, and the arm portion 1144 being coupled to the elongate portion 1143 and extending in a second direction X different from the first direction Z.

[0082] In some embodiments, referring to FIG. 11, the method 500 further includes injecting a gas G into the mold cavity 103 and / or the hollow space 112a after engaging the first mold 101 and the second mold 102 to increase the pressure within the mold cavity 103 and / or the hollow space 112a. In some embodiments, the gas is injected through a pressure regulation system 106 associated with the mold cavity 103 until it is sensed that the mold cavity 103 has a first predetermined pressure before injecting the molding material 103' into the mold cavity 103. In some embodiments, the gas G is injected into the mold cavity 103 through the first gas conduit 1061. In some embodiments, the gas G is any suitable gas as required, for example, air, but the present invention is not limited thereto. In some embodiments, after engaging the outlet 111o and the supply port 114, the pressure within the mold cavity 103 of the molding apparatus 100 is adjusted to a first predetermined pressure. After the molding apparatus 100 reaches the first predetermined pressure, the injection is started. In some embodiments, the gas G is air or the like.

[0083] In some embodiments, the pressure sensing unit 1066 senses that the pressure in the mold cavity 103 is the atmospheric pressure. In some embodiments, the first valve 1064 is opened so that the gas G is injected into the mold cavity 103 through the first gas conduit 1061. In some embodiments, the gas G is injected into the mold cavity 103 through the pressure regulating system 106 when the supply port 114 is closed. In some embodiments, the gas G is injected into the mold cavity 103 through the supply port 104.

[0084] In some embodiments, during the process of injecting the gas G into the mold cavity 103, the pressure in the mold cavity 103 is continuously sensed. In some embodiments, the pressure sensing unit 1066 continuously senses the pressure in the mold cavity 103, and the gas G is injected into the mold cavity 103 until the mold cavity 103 senses that it has reached a first predetermined pressure, and then the first valve 1064 and the second valve 1065 of the pressure regulating system 106 are closed to stop the injection of the gas G into the mold cavity 103. In some embodiments, the first predetermined pressure is higher than the atmospheric pressure. In some embodiments, the first predetermined pressure is lower than the atmospheric pressure.

[0085] In some embodiments, before operation 508, the mold cavity 103 reaches a first predetermined pressure and the first valve 1064 and the second valve 1065 of the pressure regulating system 106 are closed.

[0086] In some embodiments, the method 500 includes an operation 508 of injecting the molding material 113' into the hollow space 112a from the extrusion system 110 through the supply port 104 and the opening 112b, and the molding material 113' includes a polymer material and a foaming agent. In some embodiments

[0087] In some embodiments, the molding material 113' is produced by the extrusion system 110, and the molding material 113' is discharged from the injection unit 150 and flows into the hollow space 112a of the part 112 through the discharge channel 111, the supply port 104, and the opening 112b. In some embodiments, referring to FIG. 12, the molding material 113' is injected into the mold cavity 103 through the outlet 111o and the supply port 104. In some embodiments, the discharge channel 111 is at least partially surrounded by the molding apparatus 100 when injecting the molding material 113'.

[0088] In some embodiments, a single shot of the molding material 113' is injected to fill the entire hollow space 112a. Since the part 112 is elastic, the part 112 and the hollow space 112a may expand during or after the injection of the molding material 113' into the hollow space 112a. The volume of the hollow space 112a increases during or after the injection of the molding material 113'. In some embodiments, after the injection of the molding material 113' into the hollow space 112a, the hollow space 112a continues to expand because the molding material 113' undergoes physical foaming within the hollow space 112a.

[0089] In some embodiments, during operation 508, during the process of injecting the molding material 113' into the hollow space 112a, the pressure within the mold cavity 103 changes rapidly, and the pressure sensing unit 1066 continuously senses the pressure within the mold cavity 103. In some embodiments, the molding material 113' is injected from the supply port 104 into the hollow space 112a, and a first predetermined pressure is applied to the molding material 113'. In some embodiments, the molding material 113' and the gas G are disposed within the mold cavity 103 or the hollow space 112a, and the molding material 113' expands and foams within the hollow space 112a.

[0090] In some embodiments, the molding material 113' is injected from the supply port 104 and the opening 112b into the hollow space 112a, increasing the pressure within the mold cavity 103. In some embodiments, the pressure within the mold cavity 103 of the molding apparatus 100 rises beyond a first predetermined pressure. In some embodiments, the pressure within the mold cavity 103 of the molding apparatus 100 rises from a first predetermined pressure to a second predetermined pressure.

[0091] In some embodiments, after the molding material 113' is injected into the hollow space 112a within the mold cavity 103 having the first predetermined pressure, the pressure within the mold cavity 103 increases. Thus, the setting of the second predetermined pressure ensures that the mold cavity 103 is maintained within an appropriate pressure range. In some embodiments, when the mold cavity 103 reaches the second predetermined pressure, the injection of the molding material 113' into the hollow space 112a is stopped.

[0092] In some embodiments, the process of injecting the molding material 113' into the hollow space 112a within the mold cavity 103 having the first predetermined pressure lasts less than 3 seconds. In some embodiments, since the mold cavity 103 has the first predetermined pressure, the completion of the filling of the molding material 113' may last less than 0.5 seconds. During the injection period or at the instant of injection completion, the pressure within the mold cavity 103 is sensed in real time by the pressure sensing unit 1066 and pressure information is provided. Therefore, the pressure adjustment system 106 can adjust the pressure within the mold cavity 103 according to the pressure information, and thus the pressure within the mold cavity 103 can be maintained within a predetermined pressure range. In some embodiments, during the injection process, the temperature of the discharge channel 111 is higher than the temperature of the molding apparatus 100. In some embodiments, in order to maintain the mold cavity 103 or the hollow space 112a at a predetermined pressure level, a force is applied to the first mold 101 and / or the second mold 102 during or after the injection of the molding material 113'. In some embodiments, the pressure level is suitable for physical foaming.

[0093] In some embodiments, method 500 includes operations 509 and 510. Operation 509 includes foaming the molding material 113’ to form the foamed member 113, and the foamed member 113 expands within the mold cavity 103 during the formation of the foamed member 113. Operation 510 includes expanding the component 112 during or after the injection of the molding material 113’ into the hollow space 112a. In some embodiments, operation 509 of method 500 is similar to operation 406 of method 400.

[0094] In some embodiments, after the injection of the molding material 113’, the molding material 113’ undergoes physical foaming within the mold cavity 103 as shown in FIG. 13 and becomes the foamed member 113 as shown in FIG. 14. Referring to FIGS. 13 and 14, the component 112 expands during the formation of the foamed member 113 until the component 112 contacts the inner wall 105 of the mold cavity. In some embodiments, the hollow space 112a expands until the component 112 is in full contact with the inner wall 105 of the mold cavity 103.

[0095] In some embodiments, during the physical foaming of the molding material 113’ or after the formation of the foamed member 113, method 500 further includes discharging at least a portion of the gas G from the mold cavity 103 and / or the hollow space 112a. In some embodiments, a portion of the gas G is released from the mold cavity 103 after injecting the gas G into the mold cavity 103. In some embodiments, during operations 509 and 510, the gas G is discharged from the mold cavity 103 through the pressure regulating system 106 in less than 1 second while the molding material 113’ is foaming within the hollow space 112a or while the foamed member 113 is being formed. Due to the discharge of a portion of the gas G, the molding material 113’ within the mold cavity 103 after the foaming process may have a lower density. In some embodiments, the gas G is discharged from the mold cavity 103 through the joint point 107. In some embodiments, the pressure within the mold cavity 103 decreases from a second predetermined pressure.

[0096] In some embodiments, the pressure in the mold cavity 103 and / or the hollow space 112a is reduced to a third predetermined pressure by discharging a part of the gas G. The pressure in the mold cavity 103 or the hollow space 112a is reduced by discharging a part of the gas G from the mold cavity 103 and / or the hollow space 112a, and / or by discharging a part of the physical foaming agent released from the molding material 113' from the mold cavity 103 and / or the hollow space 112a.

[0097] In some embodiments, when the pressure sensing unit 1066 senses that the pressure in the mold cavity 103 is greater than a second predetermined pressure, a part of the gas G in the mold cavity 103 is discharged until the pressure in the mold cavity 103 is within a predetermined pressure range. In some embodiments, the predetermined pressure range is between a first predetermined pressure and a second predetermined pressure. In some embodiments, the second valve 1065 is open, and a part of the gas G in the mold cavity 103 is discharged through the second gas conduit 1062.

[0098] In some embodiments, the method 500 includes an operation 511. The operation 511 includes disengaging the first mold 101 and the second mold 102 after the foaming member 113 is formed.

[0099] In some embodiments, referring to FIG. 15, after the foaming member 113 is formed, the discharge channel 111 is disengaged from the supply port 104 before or after the first mold 101 and the second mold 102 are disengaged. The article 119 including the foaming member 113 and the component 112 is formed in the mold cavity 103 as shown in FIG. 14. The foaming member 119 is in direct contact with the inner surface 112c of the component 112. The article 119 formed in this way does not contain an adhesive.

[0100] The discharge port 111o is detached from the supply port 104. The molding apparatus 100 is changed from a closed configuration (FIGS. 8 and 11 to 14) to an open configuration.

[0101] In some embodiments, method 500 includes operation 512. Operation 512 includes removing article 119, which includes component 112 and foam member 113, from molding device 100.

[0102] In some embodiments, referring to FIG. 16, after disengaging first mold 101 and second mold 102, article 119 can be removed from mold cavity 103. In some embodiments, after forming article 119, article 119 is then removed from first mold 101. In some embodiments, article 119 is removed manually by a human or automatically by a robot, a robotic arm, a gripper, etc.

[0103] In some embodiments, method 500 further includes trimming the sides of article 119. Referring to FIG. 17, the sides of article 119 are trimmed such that article 119 having foam member 113 is disposed between first portion 112d of component 112 and second portion 112e of component 112 separated from first portion 112d.

[0104] In some embodiments, the thickness of component 112 is substantially thinner than the thickness of foam member 113. In some embodiments, the overall thickness T of article 119 is substantially less than 2 mm. In some embodiments, the overall thickness T of article 119 is substantially less than 1 mm. In some embodiments, the thickness of foam member 113 is substantially less than 1 mm. In some embodiments, the thickness of foam member 113 is substantially less than 0.5 mm. Foam member 113 is directly attached to first portion 112d and second portion 112e with no additional components or materials (such as adhesives) disposed therebetween. In some embodiments, component 112 is softer than foam member 113. In some embodiments, foam member 113 has a density of about 0.05 to about 0.5.

[0105] In some embodiments, method 500 includes the following operations. In some embodiments, the steps described below can be repeated and automatically executed. In some embodiments, the above-described injection molding system 300 as shown in FIG. 3 is used by method 500. FIGS. 18-24 are schematic cross-sectional views of one or more operations of method 500 for manufacturing an article according to some embodiments of the present disclosure.

[0106] In some embodiments, in operation 503, the injection unit 150 and the molding device 100 are first provided as shown in FIG. 18. The molding device 100 is in an open configuration, the discharge channel 111 is disengaged from the supply port 104, and the first mold 101 is disengaged from the second mold 102.

[0107] In some embodiments, the supply port 104 has a first partial port 104a on the first side wall 101s of the first mold 101 and a second partial port 104b on the second side wall 102s of the second mold 102. In some embodiments, the first partial port 104a and the second partial port 104b are separated from each other when the molding device 100 is in the open configuration as shown in FIG. 18.

[0108] In some embodiments, in operation 504, the part 112 is disposed between the first mold 101 and the second mold 102 as shown in FIG. 19. In some embodiments, the opening 112b faces the first partial port 104a or the second partial port 104b, and the opening 112b is engageable with the first partial port 104a and / or the second partial port 104b.

[0109] In some embodiments, in operation 505, referring to FIG. 20, the supply port 104 is formed after the first mold 101 engages the second mold 102. In some embodiments, the supply port is formed when the molding device 100 is in a closed configuration. As a result, when the supply port 104 is formed and the opening 112b engages the supply port 104, it communicates with the hollow space 112a. In some embodiments, the formation of the supply port 104 and the engagement of the opening 112b with the supply port 104 thus formed occur simultaneously.

[0110] In some embodiments, in operation 507, referring to FIG. 21, the discharge channel 111 engages the supply port 104 and contacts the first mold 101 and the second mold 102. In some embodiments, before or after engaging the first mold 101 and the second mold 102, the discharge channel 111 is engaged with the supply port 104 in the manner described above as shown in FIG. 20 or similar to that shown in FIG. 11. In some embodiments, the discharge channel 111 is fixed to the molding device 100. In some embodiments, gas is injected into the mold cavity 103 and / or the hollow space 112a after the first mold 101 engages the second mold 102 to increase the pressure within the mold cavity 103 and / or the hollow space 112a. In some embodiments, the gas G is air or the like. In some embodiments, a force is applied to the first mold 101 and / or the second mold 102 during or after injection of the mixture 113' to maintain the mold cavity 103 and / or the hollow space 112a at a predetermined pressure level suitable for physical foaming.

[0111] In some embodiments, in operation 508, referring to FIGS. 21 and 22, after the first mold 101 and the second mold 102 are engaged, the molding material 113' is injected into the hollow space 112a in the same manner as described above or as shown in FIGS. 12 and 13. In some embodiments, the gas G is injected into the hollow space 112a or the mold cavity 103 before injecting the molding material 113' into the hollow space 112a. The molding material 113' is discharged from the injection unit 150 and flows into the hollow space 112a of the component 112 through the discharge channel 111, the supply port 104, and the opening 112b. In some embodiments, a one-shot mixture 113' is injected to fill the entire hollow space 112a.

[0112] In some embodiments, in operation 509, referring to FIGS. 22 and 23, after injecting the molding material 113', the molding material 113' undergoes physical foaming in the molding cavity 103 to become the foamed member 113 in the same manner as shown above or as shown in FIGS. 13 and 14. In some embodiments, during the physical foaming of the molding material 113' or after the formation of the foamed member 113, at least a part of the gas G is discharged from the mold cavity 103 and / or the hollow space 112a, and / or a part of the physical foaming agent released from the molding material 113' is discharged from the mold cavity 103 and / or the hollow space 112a, thereby reducing the pressure in the mold cavity 103 and / or the hollow space 112a.

[0113] In some embodiments, in operation 510, still referring to FIGS. 22 and 23, since the component 112 is elastic, the molding material 113' may expand during or after the injection of the molding material 113' into the hollow space 112a. The volume of the hollow space 112a increases during or after the injection of the molding material 113'. In some embodiments, the hollow space 112a expands until the component 112 is in full contact with the inner wall 105 of the mold cavity 103, as shown in FIG. 22. In some embodiments, after injecting the mixture 113' into the hollow space 112a, the mixture 113' undergoes physical foaming in the hollow space 112a, so the hollow space 112a continues to expand.

[0114] In some embodiments, in operation 510, referring to FIG. 24, after the foam member 113 is formed in the mold cavity 103, the first mold 101 is disengaged from the second mold 102 in a manner similar to that described above or shown in FIG. 15. In some embodiments, the discharge channel 111 is disengaged from the supply port 104 before or after the first mold 101 and the second mold 102 are disengaged. The article 119 thus formed is similar to that shown in FIG. 16. In some embodiments, after the article 119 is removed from the mold cavity 103, the side surface of the article 119 is trimmed as shown in FIG. 17. As a result, an article 119 having a foam member 113 between a first portion 112d of the component 112 and a second portion 112e of the component 112 is formed.

[0115] The above outlines the features of some embodiments so that those skilled in the art can better understand aspects of the present disclosure. Those skilled in the art should understand that the present disclosure can be readily used as a basis for designing or modifying other processes and structures for the purpose of achieving the same objectives and / or achieving the same advantages as the embodiments presented herein. Those skilled in the art should also recognize that such equivalent configurations do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and modifications can be made herein without departing from the spirit and scope of the present disclosure.

[0116] Furthermore, the scope of the present application is not intended to be 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 those skilled in the art from the disclosure of the present invention, processes, machines, manufactures, compositions of matter, means, methods, or steps that presently exist or are later developed and 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 invention. Accordingly, the appended claims are intended to include such processes, machines, manufactures, compositions of matter, means, methods, and steps within their scope.

Claims

1. A method of manufacturing an article, comprising: providing a molding apparatus having a first mold and a second mold; placing a component between the first mold and the second mold, the component including a hollow space and an opening communicating with the hollow space; engaging the opening with the first mold or the second mold; engaging the first mold with the second mold to form a mold cavity surrounding the component, the opening engaging a supply port of the molding apparatus capable of communicating with the hollow space; injecting a molding material into the hollow space through the supply port and the opening, the molding material including a polymer material and a blowing agent; foaming the molding material to form a foamed member; wherein the foamed member is in contact with the inner surface of the component.

2. further comprising expanding the component during or after injection of the molding material into the hollow space; wherein the component expands until the component contacts the inner sidewall of the mold cavity, according to the method of Claim 1.

3. The supply port is formed after engagement of the first mold and the second mold, according to the method of Claim 1.

4. The supply port is disposed on a first sidewall of the first mold or a second sidewall of the second mold, according to the method of Claim 1.

5. The supply port is disposed between the first mold and the second mold, the supply port including a first partial port in the first mold and a second partial port in the second mold, the first partial port being aligned with the second partial port when the molding apparatus is in a closed configuration, according to the method of Claim 1.

6. before injecting the molding material, further comprising injecting a gas into the mold cavity or the hollow space after engagement of the first mold and the second mold to increase the pressure in the mold cavity or the hollow space; wherein according to the method of Claim 1.

7. after injecting the molding material, further comprising discharging a gas from the mold cavity or the hollow space to decrease the pressure in the mold cavity or the hollow space;

8. A method of manufacturing an article, comprising: Providing a molding apparatus having a first mold and a second mold; Placing a part between the first mold and the second mold, the part including a hollow space and an opening communicating with the hollow space; Engaging the opening with the first mold or the second mold; Engaging the first mold with the second mold to form a mold cavity surrounding the part, wherein the opening engages with a supply port of the molding apparatus that can communicate with the hollow space, the supply port is disposed on a side wall of the molding apparatus, and the part is disposed within the mold cavity; Injecting a molding material into the hollow space through the supply port and the opening; Foaming the molding material to form a foamed member; Including; The hollow space expands within the mold cavity during formation of the foamed member, a method.

9. After forming the foamed member, disengaging the first mold from the second mold; Removing the article including the part and the foamed member from the molding apparatus; The method according to claim 8, further comprising.

10. A portion of the part adjacent to the opening is inserted into the supply port when the opening engages with the supply port, the method according to claim 8.

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