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: an extrusion system; a molding apparatus including a discharge channel and first and second mold cavities; and a pressure regulating system for regulating pressure within the first and second mold cavities. An injection molding method includes: a process of providing a molding apparatus having the first and second mold cavities, a first supply port in communication with the first mold cavity, and a second supply port in communication with the second mold cavity; a process of injecting a first gas into the first mold cavity until the first mold cavity is sensed to have a first predetermined pressure, by sensing the first pressure in the first mold cavity; and a process of injecting a second gas into the second mold cavity until the second mold cavity is sensed to have a second predetermined pressure, by sensing the second pressure in the second mold cavity. The first and second predetermined pressures are different.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Patent Application No. 18 / 062,240, filed December 6, 2022, which is incorporated by reference in its entirety.

[0002] Technical Field 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 using a molding device having a plurality of mold cavities with different pressures. [Background technology]

[0003] Foamed polymer materials have many advantages, such as high strength, low weight, impact resistance, and thermal insulation. Foamed polymer articles can be made by injection molding or extrusion. For example, a polymer material is melted and mixed with a blowing agent to form a mixture, and then a force or pressure is applied to the mixture to inject or extrude the mixture into a mold cavity, where the mixture expands to form the foamed polymer article. It is necessary to provide a foamed polymer article with desirable properties. Summary of the Invention [Problem to be solved by the invention]

[0004] SUMMARY OF THE INVENTION It is an object of the present invention to provide an injection molding system and method. [Means for solving the problem]

[0005] According to one embodiment of the present disclosure, an injection molding system is disclosed, the injection molding system including an extrusion system, a first discharge channel, a molding device, and a pressure regulation system.

[0006] The extrusion system is configured to produce a mixture of a polymeric material and a blowing agent. The first discharge channel is in communication with the extrusion system and includes a first outlet configured to discharge the mixture from the extrusion system. The molding apparatus is configured to receive the mixture from the first outlet. The pressure regulation system is coupled to the molding apparatus. The molding apparatus includes a first mold cavity, a second mold cavity separated from the first mold cavity, a first supply port in communication with the first mold cavity and engageable with the first outlet, and a second supply port in communication with the second mold cavity and engageable with the first outlet, and the pressure regulation system is configured to regulate pressure within the first mold cavity and the second mold cavity.

[0007] According to one embodiment of the present disclosure, there is disclosed a method of injection molding, the method including the steps of providing a molding apparatus including a first mold cavity and a second mold cavity, a first supply port in communication with the first mold cavity, and a second supply port in communication with the second mold cavity, sensing a first pressure in the first mold cavity and injecting a first gas into the first mold cavity until the first mold cavity is sensed to have a first predetermined pressure, and sensing a second pressure in the second mold cavity and injecting a second gas into the second mold cavity until the second mold cavity is sensed to have a second predetermined pressure, the first predetermined pressure being different from the second predetermined pressure.

[0008] According to one embodiment of the present disclosure, another injection molding method is disclosed, the method including the steps of: providing an extrusion system configured to produce a mixture of a polymeric material and a blowing agent, and a discharge channel in communication with the extrusion system and including an outlet, the outlet being engageable with a first supply port and a second supply port; providing a molding apparatus including first and second mold cavities, the first supply port in communication with the first mold cavity, and a second supply port in communication with the second mold cavity; engaging the outlet with the first supply port; injecting a first amount of the mixture through the outlet and the first supply port into the first mold cavity; and disengaging the outlet from the first supply port. The method further includes engaging the outlet with the second supply port, injecting a second amount of the mixture through the outlet and the second supply port into the second mold cavity, disengaging the outlet from the second supply port, sensing a first pressure in the first mold cavity containing the first amount of the mixture and injecting a first gas into the first mold cavity or venting a portion of the gas from the first mold cavity until the first mold cavity is sensed to have a first predetermined pressure, and sensing a second pressure in the second mold cavity containing the second amount of the mixture and injecting a second gas into the second mold cavity or venting a portion of the gas from the second mold cavity until the second mold cavity is sensed to have a second predetermined pressure, the first predetermined pressure being different from the second predetermined pressure. [Brief explanation of the drawings]

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

[0010] [Figure 1] FIG. 1 is a schematic diagram of an injection molding system according to one embodiment of the present invention. [Figure 2] FIG. 2 is a schematic diagram of a portion of the injection molding system of FIG. 1 according to one embodiment of the present invention. [Figure 3] FIG. 3 is an enlarged view of a portion of the injection molding system enclosed by the dashed line in FIG. 2, according to one embodiment of the present invention. [Figure 4] FIG. 4 is a schematic diagram of an injection molding system according to one embodiment of the present invention. [Figure 5] FIG. 5 is a schematic diagram of a portion of an injection molding system according to one embodiment of the present invention. [Figure 6] FIG. 6 is a schematic diagram of a portion of an injection molding system according to one embodiment of the present invention. [Figure 7] FIG. 7 is a top view of a portion of an injection molding system according to one embodiment of the present invention. [Figure 8] FIG. 8 is a schematic diagram of a portion of an injection molding system according to one embodiment of the present invention. [Figure 9] FIG. 9 is a schematic diagram of a portion of the injection molding system of FIG. 1 according to one embodiment of the present invention. [Figure 10] FIG. 10 is a schematic diagram of a portion of the injection molding system of FIG. 1 according to one embodiment of the present invention. [Figure 11A] 11A and 11B collectively show a flow chart of an injection molding method according to one embodiment of the present invention. [Figure 11B] 11A and 11B collectively show a flow chart of an injection molding method according to one embodiment of the present invention. [Figure 12] FIG. 12 is a schematic diagram illustrating an exemplary operation of an injection molding method according to one embodiment of the present disclosure. [Figure 13] FIG. 13 is a schematic diagram illustrating an exemplary operation of an injection molding method according to one embodiment of the present disclosure. [Figure 14] FIG. 14 is a schematic diagram illustrating an exemplary operation of an injection molding method according to one embodiment of the present disclosure. [Figure 15] FIG. 15 is a schematic diagram illustrating an exemplary operation of an injection molding method according to one embodiment of the present disclosure. [Figure 16] FIG. 16 is a schematic diagram illustrating an exemplary operation of an injection molding method according to one embodiment of the present disclosure. [Figure 17] FIG. 17 is a schematic diagram illustrating an exemplary operation of an injection molding method according to one embodiment of the present disclosure. [Figure 18] FIG. 18 is a schematic diagram illustrating an exemplary operation of an injection molding method according to one embodiment of the present disclosure. [Figure 19] FIG. 19 is a schematic diagram illustrating an exemplary operation of an injection molding method according to one embodiment of the present disclosure. [Figure 20A] 20A and 20B collectively show a flow chart of an injection molding method according to one embodiment of the present invention. [Figure 20B] 20A and 20B collectively show a flow chart of an injection molding method according to one embodiment of the present invention. [Figure 21] FIG. 21 is a schematic diagram illustrating an exemplary operation of an injection molding method according to one embodiment of the present disclosure. [Figure 22] FIG. 22 is a schematic diagram illustrating an exemplary operation of an injection molding method according to one embodiment of the present disclosure. [Figure 23] FIG. 23 is a schematic diagram illustrating an exemplary operation of an injection molding method according to one embodiment of the present disclosure. [Figure 24] FIG. 24 is a schematic diagram illustrating an exemplary operation of an injection molding method according to one embodiment of the present disclosure. [Figure 25] FIG. 25 is a flow chart illustrating an injection molding method according to one embodiment of the present invention. [Figure 26A] 26A and 26B collectively show a flow chart of an injection molding method according to one embodiment of the present invention. [Figure 26B] 26A and 26B collectively show a flow chart of an injection molding method according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0011] The following disclosure provides many different embodiments or examples for implementing different features of the provided subject matter. To simplify the 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 on or above a second feature in the following description 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 and second features, and therefore the first and second features may not be in direct contact. In addition, the disclosure may repeat reference numerals and / or letters in various examples. This repetition is for purposes of brevity and clarity and does not in itself dictate a relationship between the various embodiments and / or configurations discussed.

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

[0013] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. However, any numerical value inherently contains 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 an acceptable standard error of the mean, as considered by one of ordinary skill in the art. Other than in the operating examples / examples, or unless otherwise expressly stated, all numerical ranges, amounts, values, and percentages disclosed herein, such as amounts of materials, durations of time, temperatures, operating conditions, ratios of amounts, etc., should be understood to be modified in all instances by the term "about." Accordingly, unless otherwise specified, the numerical parameters set forth in this disclosure and the appended claims are approximations that can be varied as desired. At the very least, each numerical parameter should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Ranges may be expressed herein as from one endpoint to another endpoint, or between two endpoints. All ranges disclosed herein include the endpoints unless otherwise stated.

[0014] FIG. 1 is a schematic diagram of an injection molding system 100 according to one embodiment of the present invention. The injection molding system 100 includes an extrusion system 10, a discharge channel 20, a molding apparatus 30a, and a pressure regulation system 36. The extrusion system 10 is configured to generate a mixture of a polymeric material and a blowing agent and inject (inject) the mixture into the discharge channel 20. The extrusion system 10 is connected to or in communication with the discharge channel 20. The discharge channel 20 includes an outlet 21 configured to discharge the mixture from the extrusion system 10. The discharge channel 20 includes a first discharge channel 20a. In some embodiments, the first discharge channel 20a is in communication with the extrusion system 10 and includes a first outlet 21a, which is disposed distal to the extrusion system 10 and configured to discharge the mixture from the extrusion system 10. The molding apparatus 30a is configured to receive the mixture from the first outlet 21 of the first discharge channel 20a. A pressure regulation system 36 is coupled to the molding apparatus 30a.

[0015] In some embodiments, the polymeric material comprises a high molecular weight polymer. In some embodiments, the polymeric material comprises ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), or the like. In some embodiments, the polymeric material comprises a foamable material. In some embodiments, the blowing agent is a physical or chemical additive that releases a gas, thereby forming pores in the resulting foamed polymeric article. In some embodiments, the blowing agent is a physical additive. Physical blowing agents include atmospheric gases (e.g., nitrogen or carbon dioxide), hydrocarbons, chlorofluorocarbons, noble gases, or combinations thereof. The blowing agent may be supplied in any flowable physical state, such as a gas, liquid, or supercritical fluid (SCF).

[0016] 2 is a schematic diagram of an extrusion system 10 according to some embodiments of the present disclosure. The extrusion system 10 includes a melting section 120, a mixing section 130, a blowing agent supply section 140, an injection section 150, a first flow control element 161, a second flow control element 162, and a monitoring module 180.

[0017] In some embodiments, melting section 120 is configured to convey a polymeric material, as shown in Figure 2. In some embodiments, melting section 120 includes a pushing cartridge 121, a first supply passage 122, a first discharge passage 123, and a pushing member 124. In some embodiments, melting section 120 further includes a supply hopper 125.

[0018] In some embodiments, the first supply passage 122 and the first discharge passage 123 are respectively disposed at opposite ends of the pressing cartridge 121. In some embodiments, the first supply passage 122 communicates with the interior space 1211 of the pressing cartridge 121, and the first discharge passage 123 communicates with the exterior space of the pressing cartridge 121, and the first supply passage 122 is configured to deliver the polymer material to the interior space 1211 of the pressing cartridge 121. In some embodiments, the supply hopper 125 is configured to deliver the polymer material to the interior space 1211 of the pressing cartridge 121 through the first supply passage 122.

[0019] The pressing member 124 is configured to transport the polymer material from the first supply passage 122 to the first discharge passage 123. In some embodiments, the pressing member 124 is disposed in the internal space 1211 of the pressing cartridge 121. In some embodiments, the pressing 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 pressing member 124 is rotatable relative to the pressing cartridge 121. In some embodiments, the polymer material is transported from the first supply passage 122 to the first discharge passage 123 by rotation of the pressing member 124. In some embodiments, the pressing member 124 is immovable in a direction parallel to the longitudinal axis of the pressing cartridge 121.

[0020] In some embodiments, the length of the pressing 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 pressing member 124 to the diameter D2 of the pressing member 124 is within a range of about 1:1500 to about 1:4500, and the polymer material melted by the melting zone 120 may be homogenized. In some embodiments, the shortest distance D1 between the inner sidewall 1212 of the pressing cartridge 121 and the pressing 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 pressing member 124 is within a range of 0.01 to 0.05 mm.

[0021] The mixing section 130 is configured to receive the polymer material from the melting section 120 and mix the polymer material with the blowing agent to form a mixture of the polymer material and the blowing agent. The mixing section 130 includes a hollow mixing cartridge 131, a second supply passage 132, a second discharge passage 133, and a mixing rotor 134.

[0022] The second supply passage 132 and the second discharge passage 133 are each disposed at opposite 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 mixture.

[0023] The mixing rotor 134 is configured to mix the polymeric material with the blowing agent to form a mixture 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 agitate the mixture within the mixing cartridge. The mixing rotor 134 is rotatable to mix the polymeric material with the blowing agent and to transport the mixture of the polymeric material and the blowing agent from the second supply passage 132 to the second discharge passage 133. In some embodiments, the mixing rotor 134 is immovable in a direction parallel to the longitudinal axis of the mixing cartridge 131.

[0024] 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 sidewall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 to the diameter D4 of the mixing rotor 134 is within a range of about 1:1500 to about 1:4500, so that the mixture prepared by the extrusion system 10 may be uniform and homogenized. In some embodiments, the mixture may be divided into multiple portions, and the ratio of blowing agent to polymeric material in each portion of the mixture prepared by the extrusion system 10 is substantially constant. In some embodiments, the ratio of polymeric material to blowing agent in a first portion of the mixture is substantially equal to the ratio of polymeric material to blowing agent in a second portion of the mixture. In some embodiments, the shortest distance D3 between the inner sidewall 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 sidewall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 is in the range of 0.01 to 0.09 mm.

[0025] 3 is an enlarged view of a portion of an extrusion system according to aspects of the present disclosure in some embodiments. To ensure uniform mixing of the molten polymer material and the blowing agent within the mixing cartridge 131, in some embodiments, as shown in FIGS. 2 and 3 , the mixing rotor 134 further includes a cylindrical pillar 1341 rotatably disposed within the mixing cartridge 131 and a groove 1342 annularly disposed around the pillar 1341. Therefore, as the pillar 1341 rotates, the polymer material and the blowing agent are agitated by the groove 1342, achieving the desired mixing effect. In some embodiments, the shortest distance D3 is the shortest distance between the groove 1342 and the inner sidewall 1311 of the hollow mixing cartridge 131.

[0026] In some embodiments, the minimum distance D3 is in the range of 0.01 to 0.09 mm when the minimum distance D3 is the minimum distance between the groove 1342 and the inner sidewall 1311 of the hollow mixing cartridge 131. In some embodiments, the diameter D4 of the mixing rotor 134 is in the range of 45 to 75 mm.

[0027] In some embodiments, the melting zone 120 includes a hollow pressing cartridge 121 configured to contain the polymeric material and having a first pressure, and the mixing zone 130 includes a hollow mixing cartridge 131 having a second pressure. In some embodiments, the first pressure is greater than the second pressure to prevent backflow. In some embodiments, the polymeric material is drawn from the melting zone 120 toward the mixing zone 130 by the difference between the first and second pressures.

[0028] The blowing agent supply unit 140 is connected to the mixing unit 130 and configured to deliver the blowing agent to the mixing unit 130. In some embodiments, the blowing agent supply unit 140 is disposed between the first flow control element 161 and the second flow control element 162. In some embodiments, the blowing agent supply unit 140 is disposed proximal to the first flow control element 161 and distal to the second flow control element 162.

[0029] In some embodiments, a blowing agent source (not shown) is connected to the blowing agent supply section 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 section 130 by the blowing agent supply section 140.

[0030] In some embodiments, first flow control element 161 is disposed at first port 171 connecting melting zone 120 to mixing zone 130. First port 171 is configured to introduce polymeric material from melting zone 120 to mixing zone 130. First port 171 is located between melting zone 120 and mixing zone 130. In some embodiments, first port 171 is configured to introduce polymeric material from press cartridge 121 of melting zone 120 to mixing cartridge 131 of mixing zone 130. In some embodiments, polymeric material can be transported and / or drawn from melting zone 120 to mixing zone 130 through first port 171 by a pressure differential between a first pressure and a second pressure.

[0031] In some embodiments, first flow control element 161 is disposed between melting zone 120 and mixing zone 130 and configured to control the flow of polymeric material from melting zone 120 to mixing zone 130. First flow control element 161 may be a valve, a movable cover, or the like.

[0032] In some embodiments, first flow control element 161 is configured to switch between an open configuration and a closed configuration. The open configuration of first flow control element 161 allows polymeric material to flow from melt zone 120 into mixing zone 130, and the closed configuration of first flow control element 161 prevents polymeric material from flowing back from mixing zone 130 into melt zone 120.

[0033] In some embodiments, first flow control element 161 is configured to maintain a pressure differential between melting zone 120 and mixing zone 130. In some embodiments, first flow control element 161 is configured to maintain a pressure differential between melting zone 120 and mixing zone 130 by switching between an open configuration and a closed configuration so that polymeric material cannot flow back from mixing cartridge 131 of mixing zone 130 to pressing cartridge 121 of melting zone 120. In some embodiments, first flow control element 161 is configured to adjust the first pressure and / or the second pressure to maintain a pressure differential between the first pressure and the second pressure. In some embodiments, first flow control element 161 is in the closed configuration when the first pressure is similar to the second pressure.

[0034] In some embodiments, the injection section 150 is configured to receive the mixture discharged from the second discharge passage 133 of the mixing section 130 and discharge the mixture outside the injection section 150. In some embodiments, the injection section 150 is configured to discharge the mixture, and the at least one discharge channel 20 can be in communication with the injection section 150.

[0035] In some embodiments, the injection unit 150 includes a hollow metering cartridge 151 configured to contain the mixture. The metering cartridge 151 has a hollow internal space 1511 that communicates with the second discharge passage 133 and is configured to contain the mixture. The injection unit 150 further includes a connecting passage 152 that communicates with the internal space 1511 of the metering cartridge 151, and a discharge member 153 that is slidably disposed in the internal space 1511 of the metering cartridge 151 and configured to discharge the mixture to the outside of the metering cartridge 151 through an outlet 154.

[0036] 1, in some embodiments, the discharge channel 20 corresponds to one extrusion system 10. The mixture enters the discharge channel 20 from one extrusion system 10 or outlet 154.

[0037] FIG. 4 is a schematic diagram of an injection molding system 200 according to one embodiment of the present invention. In some embodiments, as shown in FIG. 4, the injection molding system 200 includes multiple discharge channels 20. In some embodiments, the extrusion system 10 corresponds to several discharge channels 20. In some embodiments, the multiple discharge channels 20 are connected to or can communicate with the outlet 154 of the extrusion system 10. In some embodiments, each of the discharge channels 20 is attached to the outlet 154 of the injection section 150. The number of discharge channels 20 may be adjusted depending on the characteristics of the mixture. The multiple discharge channels 20 extend parallel to each other and are adjacent to each other. In some embodiments, each discharge channel 20 may accommodate a different amount of the mixture to be injected from the outlet 154. The discharge channels 20 may discharge the same or different amounts of the mixture into the molding apparatus 30a. In some embodiments, each discharge channel 20 may operate at a different temperature. In some embodiments, the discharge channel 20 includes a first discharge channel 20a and a second discharge channel 20b that can be in communication with the extrusion system 10. The first discharge channel 20a and the second discharge channel 20b have the same or different widths.

[0038] Each discharge channel 20 has an outlet 21 spaced apart from the injection section 150. In some embodiments, the outlets 21 can have different widths or diameters, and thus the multiple outlets 21 can have different flow rates for the mixture. In some embodiments, the multiple outlets 21 can inject different amounts of the mixture. In some embodiments, the second discharge channel 20b includes a second outlet 21b configured to discharge the mixture from the extrusion system 10 into at least one of the first mold cavity 31a and the second mold cavity 31b. Each of the discharge channels 20 may move, extend, or retract synchronously or separately. In some embodiments, the outlet 21 of a corresponding discharge channel 20 may extend into and retract from the molding apparatus 30a.

[0039] The molding apparatus 30a of the injection molding system 100 shown in FIG. 1 and the injection molding system 200 shown in FIG. 4 will now be described. The number of molding apparatuses 30a may be adjusted as needed. In some embodiments, as shown in FIG. 1, one molding apparatus 30a corresponds to one discharge channel 20. The mixture can flow from the extrusion system 10 through one discharge channel 20 into the molding apparatus 30a. In some embodiments, as shown in FIG. 4, one molding apparatus 30a corresponds to multiple discharge channels 20. The mixture can flow from the extrusion system 10 through multiple discharge channels 20 into the molding apparatus 30a. While FIG. 4 shows two discharge channels 20 corresponding to the molding apparatus 30a for clarity and simplicity, such an example is intended for illustrative purposes only and is not intended to limit the embodiments. Those skilled in the art will readily understand that any suitable number of discharge channels 20 may be utilized.

[0040] 1 and 4, molding apparatus 30a includes a mold cavity 31 configured to receive the mixture and a supply port 35 engageable with and communicable with outlet 21. Supply port 35 is configured to dock with outlet 21. In some embodiments, molding apparatus 30a includes a first mold cavity 31a, a second mold cavity 31b separated from first mold cavity 31a, a first supply port 35a communicable with first mold cavity 31a and engageable with first outlet 21a, and a second supply port 35b communicable with second mold cavity 31b and engageable with first outlet 21a. While FIGS. 1 and 4 show only two mold cavities 31a, 31b for clarity and brevity, such examples are intended for illustrative purposes only and are not intended to limit the embodiments. Those skilled in the art will readily appreciate that any suitable number of mold cavities 31 a, 31 b may be utilized, and all such combinations are fully intended to be within the scope of the embodiments. Additionally, while mold cavities 31 a, 31 b are shown as having similar features, this is intended to be illustrative and not limiting of the embodiments, as mold cavities 31 a, 31 b may have similar or different structures to meet desired functional capabilities.

[0041] In some embodiments, molding apparatus 30a includes an upper mold base 34 and a mold below upper mold base 34. In some embodiments, the mold includes an upper mold 32 below upper mold base 34, a lower mold 33 opposite upper mold 32, and a plurality of mold cavities 31 defined by upper mold 32 and lower mold 33. In some embodiments, the plurality of mold cavities 31 includes a first mold cavity 31a and a second mold cavity 31b.

[0042] In some embodiments, the first mold cavity 31a and the second mold cavity 31b are defined by an upper mold 32 and a lower mold 33. In some embodiments, the upper mold 32 and the lower mold 33 are complementary to each other and separable. The lower mold 33 includes a plurality of lower mold cavities, and the upper mold 32 includes a plurality of upper mold cavities opposite the lower mold cavities. In some embodiments, each of the mold cavities 31 is formed by one of the upper mold cavities and a corresponding lower mold cavity. While FIGS. 1 and 4 each show one mold including two mold cavities 31 for clarity and simplicity, such examples are intended for illustrative purposes only and are not intended to limit the embodiments.

[0043] In some embodiments, each mold cavity 31 is defined by an inner top wall 311, an inner side wall 312, and an inner bottom wall 313 opposite the inner top wall 311. The inner top wall 311, the inner side wall 312, and the inner bottom wall 313 define a corresponding mold cavity 31. In some embodiments, each of the supply ports 35 communicates with the corresponding inner top wall 311.

[0044] In some embodiments, the first supply port 35a can communicate with the first mold cavity 31a and can engage with the first outlet 21a. In some embodiments, at least one first supply port 35a can communicate with the first mold cavity 31a. Each of the first supply ports 35a can communicate with a first mold cavity 31a and can engage with a corresponding first outlet 21a. In some embodiments, the first supply port 35a is located above the upper mold 32 or the lower mold 33 and can communicate with the first mold cavity 31a, the upper mold cavity, or the lower mold cavity. While FIG. 1 shows two first supply ports 35a included in one mold for clarity and simplicity, such an example is intended for illustrative purposes only and is not intended to limit the embodiments.

[0045] In some embodiments, at least one second supply port 35b can communicate with a second mold cavity 31b. Each second supply port 35b can communicate with a second mold cavity 31b and can engage with the first outlet 21a and / or the second outlet 21b. In some embodiments, the second supply port 35b is positioned above the upper mold 32 or the lower mold 33 and can communicate with the second mold cavity 31b, the upper mold cavity, or the lower mold cavity. While FIGS. 1 and 4 show one second supply port 35b in one mold for clarity and simplicity, such an example is intended for illustrative purposes only and is not intended to limit the embodiments. Those skilled in the art will readily understand that a single mold may include one or more second supply ports 35b that can communicate with a second mold cavity 31b.

[0046] In some embodiments, the discharge channel 20 is received by the upper mold base 34. In some embodiments, the first discharge channel 20a and the second discharge channel 20b are received by the upper mold base 34. In some embodiments, the first discharge channel 20a and the second discharge channel 20b are at least partially surrounded by the upper mold base 34. In some embodiments, the first supply port 35a and the second supply port 35b are configured to dock with the first outlet 21a, as shown in FIG. 1. In some embodiments, the first supply port 35a and the second supply port 35b are configured to dock with the first outlet 21a and the second outlet 21b, respectively, as shown in FIG. 4. The mixture can be transported from the discharge channel 20 through the outlet 21 and the supply port 35 into the mold cavity 31. In some embodiments, the mixture can be transported from first discharge channel 20a through first outlet 21a and first supply port 35a into first mold cavity 31a and second mold cavity 31b, as shown in FIG. 1 . In some embodiments, the mixture can be transported from second discharge channel 20b through second outlet 21b and second supply port 35b into second mold cavity 31b, as shown in FIG. 4 . In some embodiments, first supply port 35a and second supply port 35b can have different widths or diameters. In some embodiments, first supply port 35a can have different widths or diameters. In some embodiments, the mixture is injected into first mold cavity 31a and second mold cavity 31b, and then, after a period of time, a foamed polymer article is formed in first mold cavity 31a and second mold cavity 31b.

[0047] 1 and 4, the upper mold base 34 includes openings 341 configured to receive the discharge channels 20. Each opening 341 extends through the upper mold base 34. The upper mold base 34 may be attached to the upper mold 32 by screws, clamps, fasteners, or the like. In some embodiments, the material of the upper mold base 34 is the same as the material of the upper mold 32. In some embodiments, the width of the upper mold base 34 is greater than the width of the upper mold 32 or the lower mold 33. In some embodiments, the number of openings 341 corresponds to the number of mold cavities 31.

[0048] A pressure regulation system 36 is coupled to molding apparatus 30a. Pressure regulation system 36 is configured to regulate the pressure within each of first mold cavity 31a and second mold cavity 31b. In some embodiments, after the mixture is injected into mold cavity 31, the pressure within mold cavity 31 increases, and pressure regulation system 36 may release some gas to ensure mold cavity 31 is maintained within an appropriate pressure range. In some embodiments, pressure regulation system 36 is configured to regulate or reduce the pressure within mold cavity 31.

[0049] In some embodiments, each of the mold cavities 31 is coupled to one or more pressure regulation systems 36. In some embodiments, each of the mold cavities 31 may include a different number of pressure regulation systems 36 or may include no pressure regulation systems 36. In some embodiments, a first pressure regulation system 36a is coupled to the first mold cavity 31a and a second pressure regulation system 36b is coupled to the second mold cavity 31b. In some embodiments, the first mold cavity 31a and the second mold cavity 31b have different pressures.

[0050] In some embodiments, junctions 37 connect with corresponding mold cavities 31. In some embodiments, an inner sidewall 312 or an inner bottom wall 313 of a mold cavity 31 includes junctions 37. In some embodiments, junctions 37 are configured to allow fluid or gas to enter or exit the corresponding mold cavity 31.

[0051] Each pressure regulation system 36 may include a first gas conduit 361, a second gas conduit 362, a gas supply source 363, a first valve 364, a second valve 365, and a pressure sensor 366. In some embodiments, one end of the first gas conduit 361 is connected to a corresponding inner sidewall 312 or inner bottom wall 313 of the mold cavity 31. In some embodiments, one end of the first gas conduit 361 is connected to a corresponding junction 37, and the other end of the first gas conduit 361 is connected to a corresponding gas supply source 363. In some embodiments, the gas supply source 363 is configured to replenish a fluid or gas, and an appropriate fluid or gas may be replenished as needed. For example, the fluid or gas may be air, an inert gas, or the like, but the present invention is not limited thereto.

[0052] The position, shape, and number of the junctions 37 are not particularly limited and may be adjusted as needed. In some embodiments, each of the junctions 37 is a hole. In some embodiments, the junctions 37 are disposed on the corresponding inner sidewall 312 or the corresponding inner bottom wall 313 of the corresponding mold cavity 31 and penetrate the lower mold 33. In some embodiments, each of the junctions 37 is configured to supply and exhaust gas. In this regard, when the first valve 364 is opened and the corresponding second valve 365 is closed, fluid or gas is supplied to the corresponding mold cavity 31. When the first valve 364 is closed and the corresponding second valve 365 is opened, at least a portion of the fluid or gas in the corresponding mold cavity 31 is exhausted.

[0053] In some embodiments, the first supply port 35a and the second supply port 35b are located on the inner top wall 311 or the inner side wall 312 of the corresponding mold cavity 31. In some embodiments, the first supply port 35a and the corresponding junction point 37 are located on opposite sides of the first mold cavity 31a. By way of example and not limitation, the first supply port 35a is located on the inner top wall 311 and the junction point 37 is located on the inner bottom wall 313. In some embodiments, the first supply port 35a is located on the inner top wall 311 and the corresponding junction point 37 is located on the inner side wall 312 of the first mold cavity 31a. In some embodiments, the first supply port 35a is spaced from the corresponding junction point 37.

[0054] A first valve 364 is disposed in a corresponding first gas conduit 361 and configured to control whether gas from a gas source 363 enters the corresponding mold cavity 31 through the corresponding first gas conduit 361 and the corresponding junction 37. A second gas conduit 362 is coupled to the mold and in communication with the corresponding mold cavity 31. In some embodiments, the second gas conduit 362 is coupled to the corresponding junction 37. A second valve 365 is disposed in the corresponding second gas conduit 362 and configured to control whether gas from the corresponding mold cavity 31 is exhausted through the corresponding second gas conduit 362 via the corresponding junction 37.

[0055] In some embodiments, the second gas conduit 362 is connected to the corresponding first gas conduit 361 and the corresponding junction 37. In some embodiments, one end of the second gas conduit 362 is in communication with a space having a lower pressure than the pressure in the corresponding mold cavity 31, such as the external environment or a negative pressure space. However, the present invention is not limited thereto. The location at which the second gas conduit 362 connects to the corresponding first gas conduit 361 is not particularly limited. For example, the two may be connected at one end adjacent to the end at which the first gas conduit 361 connects to the corresponding junction 37. In some embodiments, the first valve 364 and the corresponding second valve 365 are not open simultaneously.

[0056] The pressure sensing unit 366 is configured to sense the pressure within the mold cavity 31. The pressure sensing unit 366 senses the pressure within the first mold cavity 31a and the second mold cavity 31b.

[0057] In some embodiments, the properties of the foamed polymer are affected by pore size and distribution throughout the polymer, which pore size and distribution are related to temperature, pressure, and feed rate. The pressure sensing unit 366 can be of any type, as long as it can sense pressure and provide pressure information after sensing the pressure within the corresponding mold cavity 31. The pressure regulation system 36 modifies the gas flow conditions to and from the corresponding mold cavity 31 according to the pressure information, so as to adjust the pressure within the corresponding mold cavity 31 so that the resulting foamed polymer article has the desired predetermined shape and properties.

[0058] In some embodiments, the pressure sensing unit 366 is located within the corresponding mold cavity 31, the first gas conduit 361, or the second gas conduit 362. In some embodiments, the pressure sensing unit 366 is located within the corresponding mold cavity 31 and is spaced apart from the corresponding supply port 35. In some embodiments, each pressure regulation system 36 has multiple pressure sensing units 366. The number and locations of the multiple pressure sensing units 366 are not particularly limited, and for example, they may be located on the inner sidewall 312 of the mold cavity 31, spaced apart from each other, and / or located anywhere in the first gas conduit 361 and / or anywhere in the second gas conduit 362. However, the present invention is not limited thereto.

[0059] In some embodiments, each of the injection molding system 100 shown in Figure 1 and the injection molding system 200 shown in Figure 4 further includes a control system 60. The control system 60 is configured to control the extrusion system 10, the discharge channel 20, and the molding apparatus 30a. In some embodiments, the control system 60 automatically controls the extrusion system 10, the discharge channel 20, and the molding apparatus 30 in real time. In some embodiments, the control system 60 is capable of communicating with the monitoring module 180 of the extrusion system 10 in real time.

[0060] In some embodiments, the control system 60 includes a central processor 61 and a plurality of sensors 62 electrically connected to or in communication with the central processor 61. In some embodiments, the sensors 62 are distributed throughout the injection molding system 100, 200 and configured to sense at least one process condition (e.g., flow rate or viscosity of the mixture through the discharge channel 20, amount of the mixture discharged from the discharge channel 20, pressure within the mold cavity 31, etc.) at predetermined locations in the injection molding system 100 (e.g., sequence of extrusion into the first and second mold cavities 31 a and 31 b, alignment of the discharge channel 20 with the first and second mold cavities 31 a and 31 b, the first and second outlets 21 a and 21 b, the first and second supply ports 35 a and 35 b, etc.). For example, at least one sensor 62 for sensing a process condition at the outlet 21 is provided at the outlet 21. In some embodiments, the sensors 62 are configured to detect process conditions and transmit signals or data based on the detected process conditions to the central processor 61 for further analysis.

[0061] In some embodiments, the control system 60 controls whether the discharge channel 20 is docked to the first supply port 35a or the second supply port 35b. In some embodiments, a cable 63 is electrically connected between the control system 60 and the extrusion system 10, the discharge channel 20, and the molding device 30a. The cable 63 is configured to transmit signals from the molding device 30a to the extrusion system 10 and the discharge channel 20.

[0062] In some embodiments, the control system 60 is configured to process pressure information detected by the pressure sensor 366 and adjust the mixing conditions of the extrusion system 10 and the extrusion rate and timing of the discharge channel 20. In some embodiments, the pressure sensor 366 provides pressure information to the control system 60, which adjusts the first valve 364 and the second valve 365 according to the pressure information. In some embodiments, the control system 60 adjusts the conditions under which gas enters and exits the mold cavity 31 in real time according to the pressure information, and adjusts the timing and amount of the mixture injected from the discharge channel 20 into the mold cavity 31 so that the injection amount and rate are within an appropriate or predetermined range during the injection molding process and so that the pressure within the mold cavity 31 is always within an appropriate or predetermined pressure range. In some embodiments, the control system 60 further controls the supply conditions of the first supply port 35 a and the second supply port 35 b and the gas replenishment conditions of the corresponding gas supply 363. In some embodiments, the control system 60 and the first valve 364, second valve 365, pressure sensing unit 366, and first and second supply ports 35a, 35b are electrically connected.

[0063] In some embodiments, the extrusion system 10 and the discharge channel 20 are positioned above one of the mold cavities 31. In some embodiments, as shown in FIG. 1, the first discharge channel 20a is movable horizontally and vertically relative to the first mold cavity 31a and the second mold cavity 31b. In some embodiments, the molding device 30a is stationary (fixed). In some embodiments, the molding device 30a is movable relative to the extrusion system 10 and the discharge channel 20. In some embodiments, the extrusion system 10 and the discharge channel 20 are stationary. In some embodiments, as shown in FIG. 4, the first discharge channel 20a is aligned with the first feed port 35a, and the second discharge channel 20b is aligned with the second feed port 35a. In some embodiments, the first discharge channel 20a and the second discharge channel 20b are movable vertically relative to the first mold cavity 31a and the second mold cavity 31b, respectively.

[0064] In some embodiments, molding apparatus 30b shown in FIG. 5 is similar to molding apparatus 30a shown in FIGS. 1 and 4. In some embodiments, as shown in FIG. 5, first gas conduit 361 is separated from corresponding second gas conduit 362, and second gas conduit 362 is coupled to corresponding mold cavity 31. In some embodiments, junction 37 of molding apparatus 30b is a hole including first opening 381 and second opening 382, where first opening 381 is a connection to first gas conduit 361 and second opening 382 is a connection to second gas conduit 362. In some embodiments, first opening 381 is configured to take in gas, and second opening 382 is configured to exhaust gas. The locations of first opening 381 and second opening 382 are not particularly limited, as long as the two openings are separated from each other. In some embodiments, first opening 381 is spaced apart from second opening 382. In some embodiments, the first opening 381 and the second opening 382 are positioned opposite each other with respect to the corresponding supply port 35. In some embodiments, the first opening 381 and the second opening 382 are positioned in the corresponding inner bottom wall 313 of the corresponding mold cavity 31. In some embodiments, the first opening 381 and the second opening 382 are positioned in the corresponding inner side wall 312 of the corresponding mold cavity 31.

[0065] In some embodiments, molding apparatus 30c shown in FIG. 6 is similar to molding apparatus 30b shown in FIG. 5. In some embodiments, as shown in FIG. 6, first opening 381 of molding apparatus 30c has a plurality of first pores 383, and second opening 382 has a plurality of second pores 384. In some embodiments, first pores 383 are each connected to first gas conduit 361, and second pores 384 are each connected to second gas conduit 362. In some embodiments, the number of second pores 384 is greater than the number of first pores 383. The locations of first pores 383 and second pores 384 are not particularly limited. They may be arranged alternately or in different regions within mold cavity 31. In some embodiments, the end of the first gas conduit 361 where it connects with the corresponding mold cavity 31 has a plurality of first guide channels 385, each of which is connected to a corresponding first pore 383 and the first gas conduit 361. In some embodiments, the end of the second gas conduit 362 where it connects with the corresponding mold cavity 31 has a plurality of second guide channels 386, each of which is connected to a corresponding second pore 384 and the second gas conduit 362.

[0066] 7, the first opening 381 of the molding apparatus 30c is located in the center of the mold cavity 31, and the second opening 382 is located on the periphery of the mold cavity 31. In some embodiments, the plurality of second pores 384 surround the first opening 381. In some embodiments, the first opening 381 and the plurality of second pores 384 are located in the inner bottom wall 313 of the mold cavity 31. In some embodiments, the diameter of each second pore 384 is smaller than the diameter of the first opening 381.

[0067] In some embodiments, as shown in FIG. 8, molding apparatus 30d includes multiple molds disposed below upper mold base 34. In some embodiments, molding apparatus 30d accommodates two or more discharge channels 20. While FIG. 8 shows molding apparatus 30d including two molds for clarity and simplicity, such example is intended for illustrative purposes only and is not intended to limit the embodiments. Those skilled in the art will readily appreciate that any suitable number of molds may be utilized, and all such combinations are fully intended to be within the scope of this embodiment.

[0068] In some embodiments, each mold receives the mixture at the same or different times. Each mold of molding apparatus 30d includes one mold cavity 31 defined therein. In some embodiments, first mold cavity 31a is defined in one mold and second mold cavity 31b is defined by another mold. In some embodiments, pressure regulation system 36 is coupled to the molds to control the pressure within first mold cavity 31a and second mold cavity 31b.

[0069] 1 and 4, in some embodiments, the injection molding system further includes a support device 40 configured to facilitate engagement of the discharge channel 20 with the molding device 30a. The support device 40 configured to facilitate engagement of the discharge channel 20 with the molding device 30a can be located at any suitable location on the injection molding system 100, 200. In some embodiments, the support device 40 is configured to support the discharge channel 20. In some embodiments, the support device 40 is used to prevent separation of the discharge channel 20 from the first supply port 35a or the second supply port 35b during injection of the mixture. In some embodiments, the control system 60 controls the support device 40 in real time. In some embodiments, the support device 40 may facilitate engagement of the discharge channel 20 with the molding devices 30b, 30c, and 30d shown in FIGS. 5, 6, and 8.

[0070] 9 is a schematic diagram of a portion of an injection molding system 100 according to one embodiment of the present disclosure. In some embodiments, as shown in FIG. 9, the support device 40 includes first and second elements 41, 42 configured to engage with each other, with the first element 41 protruding from the extrusion system 10 or discharge channel 20 and the second element 42 being disposed on the molding device 30a, although the present disclosure is not limited thereto. In some embodiments, the first and second elements 41, 42 can be fastened to each other. For example, the second element 42 is configured to receive the first element 41.

[0071] In some embodiments, the support device 40 is positioned above the mold cavity 31 of the molding apparatus 30a. In some embodiments, the first element 41 is positioned above the discharge channel 20, and the second element 42 is positioned above each molding apparatus 30a. In some embodiments, the second element 42 is positioned above the upper mold base 34 of the molding apparatus 30a. In some embodiments, the first element 41 is part of the extrusion system 10 or the discharge channel 20, and the second element 42 is part of the molding apparatus 30a. In some embodiments, the first element 41 is part of the extrusion system 10 and is positioned adjacent to the discharge channel 20, and the second element 42 is positioned above or facing the upper mold base 34 of the molding apparatus 30a. In some embodiments, the first element 41 and the second element 42 can engage with each other, thereby tightly engaging the discharge channel 20 with the upper mold base 34 of the molding apparatus 30a.

[0072] In some embodiments, the control system 60 further electrically controls the support device 40 of the molding device 30a in real time. In some embodiments, the control system 60 controls the first element 41 to be connected to the molding device 30a and controls the second element 42 to be engaged with the corresponding first element 41 for a predetermined temperature.

[0073] In some embodiments, to prevent separation of the extrusion system 10 and the molding apparatus 30a during injection of the mixture, the engaged first element 41 is subjected to a force against the second element 42. This force may be equal to or greater than a threshold value. This threshold value may be adjusted according to the pressure in the mold cavity 31 and the diameter of the outlet 21, or according to other factors.

[0074] The positions and number of the first elements 41 may be adjusted as needed and are not particularly limited. The positions and number of the second elements 42 may also be adjusted as needed and are not particularly limited. In some embodiments, the positions and number of the second elements 42 correspond to the positions and number of the first elements 41. In one embodiment, the first elements 41 may be positioned at any suitable position on the discharge channel 20, and the second elements 42 may be positioned at any suitable position on the molding apparatus 30a. In some embodiments, the second elements 42 are positioned above the upper mold 32.

[0075] FIG. 10 is a schematic diagram of a portion of an injection molding system 100 according to one embodiment of the present invention. In some embodiments, as shown in FIG. 10 , the support device 40 may be in one of two states: a locked state and an unlocked state. In the unlocked state, the first element 41 enters the corresponding second element 42 but is not yet locked to the second element 42. In other words, the first element 41 can still be withdrawn from the second element 42 when the support device 40 is in the unlocked state. In the locked state, the first element 41 enters and locks with the corresponding second element 42, and therefore the first element 41 cannot be withdrawn from the second element 42. FIG. 10 shows the support device 40 in the locked state. The support device 40 can be operated and controlled manually or automatically. The support device 40 can be switched between the two states manually or automatically.

[0076] In some embodiments, the first element 41 is rotatably fixed to the extrusion system 10. In some embodiments, the first element 41 includes a long portion 411 and an arm portion 412. The long portion 411 and the arm portion 412 are rotatable in the direction indicated by arrow A. The long portion 411 is fixed to the extrusion system 10 and extends in a first direction Z toward the upper die 32. The arm portion 412 is connected to the long portion 411 and extends in a second direction X that is substantially perpendicular to the first direction Z or a third direction Y that is substantially perpendicular to the first direction Z. In some embodiments, the first element 41 has an inverted T-shape. After the first element 41 enters the second element 42, the support device 40 changes from an unlocked state to a locked state by rotating the arm portion 412 of the first element 41. In some embodiments, the first element 41 is locked with the second element 42 by rotating the arm portion 412 of the first element 41 by approximately 90 degrees. Figure 10 shows that the arm portion 412 is locked with the second element 42 after rotating the arm portion 412 by approximately 90 degrees. As a result, the support device 40 is in a locked state, and the discharge channel 20 is tightly engaged with the molding device 30a, so that injection of the mixture from the extrusion system 10 and the discharge channel 20 into the molding device 30a can begin.

[0077] In some embodiments, the temperature of the discharge channel 20 is different from the temperature of the molding apparatus 30a. The temperature of the discharge channel 20 is higher than the temperature of the molding apparatus 30a. In some embodiments, the temperature of the discharge channel 20 may be in the range of 150°C to 200°C, and the temperature of the molding apparatus 30a may be in the range of 20°C to 60°C.

[0078] In the present disclosure, a method of injection molding is disclosed. In some embodiments, injection molding is performed by the method. The method includes several operations, and the description and illustration should not be considered a limitation on the sequence of operations. FIGS. 11A and 11B collectively show a flowchart of a method 500 of injection molding according to one embodiment of the present invention. The method 500 is not limited to the above-described embodiment. In some embodiments, the injection molding method 500 uses the injection molding system 100 described above, as shown in FIG. 1.

[0079] 12, an injection molding method 500 includes step 501, which includes providing an extrusion system 10 configured to produce a mixture of a polymeric material and a blowing agent, and a first discharge channel 20a, the first discharge channel 20a in communication with the extrusion system 10 and including a first outlet 21a, the first outlet 21a engageable with a first supply port 35a and a second supply port 35b. In some embodiments, the method 500 includes conveying the mixture from the extrusion system 10 to the first discharge channel 20a. In some embodiments, the mixture is conveyed from the extrusion system 10 to the first discharge channel 20a and accumulates within the first discharge channel 20a.

[0080] In some embodiments, method 500 includes step 502, which includes providing a molding apparatus 30a including a first mold cavity 31a and a second mold cavity 31b, a first feed port 35a in communication with the first mold cavity 31a, and a second feed port 35b in communication with the second mold cavity 31b. In some embodiments, more than one first feed port 35a is in communication with the first mold cavity 31a. In some embodiments, molding apparatus 30a is located below extrusion system 10, and extrusion system 10 is remote from molding apparatus 30a.

[0081] In some embodiments, method 500 includes step 503, which includes sensing a first pressure in first mold cavity 31a and injecting a first gas G1 into first mold cavity 31a until first mold cavity 31a is sensed to have a first predetermined pressure. In some embodiments, a first pressure sensor 366a of first pressure regulation system 36a senses the first pressure in first mold cavity 31a. In some embodiments, first gas G1 is injected into first mold cavity 31a through a first pressure regulation system 36a connected to first mold cavity 31a. In some embodiments, first gas G1 is injected into first mold cavity 31a through a first gas conduit 361 of first pressure regulation system 36a. In some embodiments, first gas G1 is any suitable gas, such as air, as needed, although the invention is not limited thereto.

[0082] In some embodiments, the first valve 364 of the first pressure regulation system 36a is opened to allow the first gas G1 to be injected into the first mold cavity 31a through the first gas conduit 361. In some embodiments, the first gas G1 is injected into the first mold cavity 31a through the first pressure regulation system 36a when the first supply port 35a is closed. In some embodiments, the first gas G1 is injected into the first mold cavity 31a through the first supply port 35a.

[0083] In some embodiments, the pressure in the first mold cavity 31a is continuously sensed during the process of injecting the first gas G1 into the first mold cavity 31a. In some embodiments, the first pressure sensing unit 366a continuously senses the first pressure in the first mold cavity 31a, and the first gas G1 is injected into the first mold cavity 31a until the first pressure sensing unit 366a senses that the first mold cavity 31a has a first predetermined pressure, at which point the first valve 364 and the second valve 365 of the first pressure regulation system 36a and the injection of the first gas G1 into the first mold cavity 31a are stopped. In some embodiments, the first predetermined pressure is greater than atmospheric pressure. In some embodiments, the first predetermined pressure is less than atmospheric pressure.

[0084] In some embodiments, method 500 includes step 504, which includes sensing a second pressure in second mold cavity 31b and injecting a second gas G2 into second mold cavity 31b until second mold cavity 31b is sensed to have a second predetermined pressure. In some embodiments, second gas G2 is injected into second mold cavity 31b through a second pressure regulation system 36b connected to second mold cavity 31b. In some embodiments, second gas G2 is injected into second mold cavity 31b through a first gas conduit 361 of second pressure regulation system 36b. In some embodiments, injection of first gas G1 and injection of second gas G2 occur simultaneously or separately.

[0085] In some embodiments, the first valve 364 of the second pressure regulation system 36b is opened to allow the second gas G2 to be injected into the second mold cavity 31b through the first gas conduit 361 of the second pressure regulation system 36b. In some embodiments, the second gas G2 is injected into the second mold cavity 31b through the second pressure regulation system 36b when the second supply port 35b is closed. In some embodiments, the second gas G2 is injected into the second mold cavity 31b through the second supply port 35b.

[0086] In some embodiments, the pressure in the second mold cavity 31b is continuously sensed during the process of injecting the second gas G2 into the second mold cavity 31b. In some embodiments, the second pressure sensing unit 366b continuously senses the second pressure in the second mold cavity 31b, and the second gas G2 is injected into the second mold cavity 31b until the second pressure sensing unit 366b senses that the second mold cavity 31b has a second predetermined pressure, at which point the first valve 364 and the second valve 365 of the second pressure regulation system 36b and the injection of the second gas G2 into the second mold cavity 31b are stopped. In some embodiments, the second predetermined pressure is higher than atmospheric pressure. In some embodiments, the second predetermined pressure is lower than atmospheric pressure.

[0087] In some embodiments, the first predetermined pressure is different from the second predetermined pressure, and in some embodiments, the first pressure and the second pressure are sensed in real time, and a control system 60 electrically connected to the molding apparatus 30a controls the first pressure and the second pressure in real time.

[0088] 13, method 500 includes step 505, which includes engaging first outlet 21a with first supply port 35a. In some embodiments, after engaging first outlet 21a with first supply port 35a, the pressure within first mold cavity 31a of molding apparatus 30a is adjusted to a first predetermined pressure.

[0089] In some embodiments, prior to engagement of the first outlet 21a with the first feed port 35a of the first molding apparatus 30a, the first discharge channel 20 is moved to a first position above the first molding apparatus 30a. In some embodiments, the first discharge channel 20a is moved horizontally to the first position above the first molding apparatus 30a. In the first position, the first discharge channel 20a is aligned with a corresponding opening 341 in the upper mold base 34 of the molding apparatus 30a. In some embodiments, the distance between the first outlet 21a and the top surface of the upper mold base 34 is greater than zero.

[0090] In some embodiments, after vertical alignment of the first discharge channel 20 with the corresponding opening 341, the first discharge channel 20a is moved toward the first mold cavity 31a and received by the corresponding opening 341 in the upper mold base 34, and then the first outlet 21a is docked with the first supply port 35a. In some embodiments, the first discharge channel 20a is moved vertically toward the first mold cavity 31a and received by the corresponding opening 341 in the upper mold base 34.

[0091] After the first outlet 21a is docked with the first supply port 35a, the first outlet 21a and the first supply port 35a form a flow path for the mixture, so that the first discharge channel 20a can communicate with the first mold cavity 31a through the first supply port 35a. In some embodiments, this flow path is formed by two or more first supply ports 35a and the first outlet 21a. The first outlet 21a must be tightly engaged with the first supply port 35a to prevent the mixture from leaking from the molding apparatus 30a.

[0092] In some embodiments, method 500 includes step 506, which includes injecting a first amount of the mixture M1 through first outlet 21a and first supply port 35a into first mold cavity 31a at a first predetermined pressure. As shown in FIG. 14 , in some embodiments, injection of the first amount of mixture M1 begins after first mold cavity 31a has the first predetermined pressure. In some embodiments, first mold cavity 31a has the first predetermined pressure before step 506, and first valve 364 and second valve 365 of first pressure regulation system 36a are closed. In some embodiments, in step 506, the first amount of mixture M1 is injected from first discharge channel 20a through first outlet 21a and first supply port 35a into first mold cavity 31a. In some embodiments, first discharge channel 20a is at least partially surrounded by molding apparatus 30a during injection of the first amount of mixture M1.

[0093] In some embodiments, step 506 further includes fixing the first discharge channel 20a to the molding apparatus 30a so as to dock the first outlet 21a with the first feed port 35a. In some embodiments, a force is provided by the support apparatus 40 to prevent separation of the extrusion system 10 from the molding apparatus 30a. In some embodiments, in step 506, when the mixture is injected from the extrusion system 10 into the molding apparatus 30a, the molding apparatus 30a may generate a reaction force opposite to the injection direction, which may be transmitted to the first discharge channel 20a and the extrusion system 10, thereby tending to separate the first discharge channel 20a from the molding apparatus 30a. In some embodiments, the support apparatus 40 provides support against the reaction force opposite to the injection direction.

[0094] In some embodiments, the first discharge channel 20a is secured to the molding apparatus 30a by engaging a first element 41 of the support apparatus 40 against a second element 42 of the support apparatus 40 to secure the first discharge channel 20a to the molding apparatus 30a, with the first element 41 protruding from the extrusion system 10 and the second element 42 disposed in the molding apparatus 30a. In some embodiments, a force is provided by the support apparatus 40 after engagement to prevent the first discharge channel 20a from separating from the molding apparatus 30a.

[0095] In some embodiments, the first discharge channel 20a is secured to the molding apparatus 30a by locking the support apparatus 40, such as by rotating a first element 41 of the support apparatus 40 relative to and within a second element 42 of the support apparatus 40, while engaging the first outlet 21a with the first supply port 35a. In some embodiments, when the first outlet 21a is docked to the first supply port 35a, the first element 41 enters and then locks with the second element 42. In some embodiments, the first discharge channel 20a is fixed to the molding device 30a by rotating the long portion 411 and the arm portion 412 of the first element 41 of the support device 40, so that the long portion 411 is fixed to the extrusion system 10 and extends in a first direction Z toward the molding device 30a, and the arm portion 412 is connected to the long portion 411 and extends in a second direction X different from the first direction Z.

[0096] In some embodiments, during the process of injecting the first amount of mixture M1 into the first mold cavity 31a of the molding apparatus 30a in step 506, the pressure within the first mold cavity 31a changes rapidly, and the first pressure sensor 366a continuously senses the first pressure within the first mold cavity 31a. In some embodiments, the first amount of mixture M1 is injected into the first mold cavity 31a of the molding apparatus 30a from the first supply port 35a, and a first predetermined pressure is applied to the first amount of mixture M1. In some embodiments, the first amount of mixture M1 and the first gas G1 are placed within the first mold cavity 31a, and the first amount of mixture M1 expands and foams within the first mold cavity 31a.

[0097] In some embodiments, the process of injecting the first amount of mixture M1 into the first mold cavity 31a at the first predetermined pressure lasts less than 1 second. In some embodiments, because the first mold cavity 31a has the first predetermined pressure, the completion of filling the first amount of mixture M1 may last less than 0.5 seconds. During the injection period or at the moment of completion of injection, the pressure in the first mold cavity 31a is sensed in real time by the first pressure sensing unit 366a, and pressure information is provided. The first pressure regulation system 36a can adjust the pressure in the first mold cavity 31a according to the pressure information, thereby maintaining the pressure in the first mold cavity 31a within a predetermined pressure range.

[0098] In some embodiments, when the first pressure in the first mold cavity 31a is sensed to be higher than a first predetermined pressure, a portion of the gas in the first mold cavity 31a is vented from the first mold cavity 31a. In some embodiments, a first amount of mixture M1 is injected from the first supply port 35a into the first mold cavity 31a of the molding apparatus 30a, thereby increasing the first pressure in the first mold cavity 31a containing the first amount of mixture M1 to a third pressure. In some embodiments, the third pressure in the first mold cavity 31a containing the first amount of mixture M1 is higher than the first predetermined pressure. In some embodiments, the pressure in the first mold cavity 31a of the molding apparatus 30a is increased from the first predetermined pressure to a third pressure.

[0099] In some embodiments, still referring to FIG. 14, method 500 includes step 507, which includes sensing a third pressure within the first mold cavity 31a having the first amount of mixture M1, and injecting a third gas into the first mold cavity or evacuating a portion of gas G3 from the first mold cavity 31a until the first mold cavity 31a is sensed to have a third predetermined pressure.

[0100] In some embodiments, after the first amount of mixture M1 is injected into the first mold cavity 31a with the first predetermined pressure, the pressure within the first mold cavity 31a increases, and therefore the setting of the third predetermined pressure ensures that the first mold cavity 31a is maintained within a suitable pressure range. In some embodiments, once the first mold cavity 31a reaches the third predetermined pressure, the injection of the third gas into the first mold cavity 31a or the evacuation of a portion of the gas G3 from the first mold cavity 31a is stopped.

[0101] In some embodiments, after injecting the third gas into the first mold cavity 31a in step 507, a portion of the gas G3 is discharged from the first mold cavity 31a. In some embodiments, step 507 further includes foaming the first amount of mixture M1 in the first mold cavity 31a and discharging the gas G3 from the first mold cavity 31a through the first pressure regulation system 36a for less than one second while the first amount of mixture M1 is foaming in the first mold cavity 31a. Due to the discharge of gas G3, the first amount of mixture M1 in the first mold cavity 31a after the foaming process may have a lower density. In some embodiments, the gas G3 is discharged from the first mold cavity 31a through the junction 37 of the first pressure regulation system 36a. In some embodiments, the gas G3 is discharged from the first mold cavity 31a during or after the foaming process of the first amount of mixture M1 in the first mold cavity 31a. In some embodiments, the third pressure within first mold cavity 31a is reduced to a third predetermined pressure.

[0102] In some embodiments, when the first pressure sensing unit 366a senses that the third pressure in the first mold cavity 31a is greater than the third predetermined pressure, the gas G3 in the first mold cavity 31a is vented until the pressure in the first mold cavity 31a falls within a predetermined pressure range. In some embodiments, the predetermined pressure range is between the first predetermined pressure and the third predetermined pressure. In some embodiments, the second valve 365 is open, and the gas G3 in the first mold cavity 31a is vented through the second gas conduit 362 of the first pressure regulation system 36a.

[0103] 15, the method 500 includes a step 508 that includes disengaging the first outlet 21a from the first supply port 35a of the molding apparatus 30a. In some embodiments, after injecting the first amount of mixture M1 into the first mold cavity 31a, the first discharge channel 20a is disengaged and moved away from the molding apparatus 30a.

[0104] In some embodiments, the support device 40 is transitioned to the unlocked state before the first outlet 21a is disengaged from the first supply port 35a. In some embodiments, the support device 40 changes from the locked state to the unlocked state by rotating a first element 41 of the support device 40 relative to and within a second element 42 of the support device 40 to unlock the discharge channel 20 from the molding device 30a. In some embodiments, while disengaging the first outlet 21a from the first supply port 35a, the first element 41 is unlocked from the second element 42 and then pulled away from the second element 42.

[0105] 16, the method 500 includes a step 509 that includes moving the first discharge channel 20a away from the first mold cavity 31a toward the second mold cavity 31b. In some embodiments, moving the first discharge channel 20 includes moving the first discharge channel 20 from a first position above the first mold cavity 31a to a second position above the second mold cavity 31b. In some embodiments, the first discharge channel 20a is moved vertically away from the first mold cavity 31a and then moved horizontally to a second position above the second mold cavity 31b.

[0106] In some embodiments, the configuration and arrangement of the second mold cavity 31b is similar to the configuration and arrangement of the first mold cavity 31a, and therefore a detailed description thereof will be omitted here for the sake of brevity.

[0107] 17 , the method 500 includes step 510, which includes engaging the first outlet 21 a with the second supply port 35 b. In some embodiments, the first outlet channel 20 a is moved toward the second mold cavity 31 b and received by the corresponding opening 341 in the upper mold base 34, and then the first outlet 21 a is docked to the second supply port 35 b. In some embodiments, the method 500 further includes securing the first outlet channel 20 a to the molding apparatus 30 a so as to dock the first outlet 21 a with the second supply port 35 b. In some embodiments, the process of securing the first outlet channel 20 a with the second supply port 35 b is similar to the process of securing the first outlet channel 20 a with the first supply port 35 a in step 506, and a detailed description thereof will be omitted here for brevity.

[0108] 18, the method 500 includes a step 511 that includes injecting a second quantity of mixture M2 through the first outlet 21 a and the second feed port 35 b into the second mold cavity 31 b with a second predetermined pressure. In some embodiments, the first quantity of mixture M1 and the second quantity of mixture M2 each have a predetermined ratio of polymeric material to blowing agent.

[0109] In some embodiments, injection of the second amount of mixture M2 begins after the second mold cavity 31b has the second predetermined pressure. In some embodiments, the second mold cavity 31b has the second predetermined pressure before step 511, and the first valve 364 and the second valve 365 of the second pressure regulation system 36b are closed. In some embodiments, in step 511, the second amount of mixture M2 is injected from the first discharge channel 20a through the first outlet 21a and the second supply port 35b into the second mold cavity 31b. In some embodiments, the first discharge channel 20a is at least partially surrounded by the molding device 30a during injection of the second amount of mixture M2. The injection of the second amount of mixture M2 is similar to step 506, and a detailed description thereof will not be repeated here.

[0110] In some embodiments, during the process of injecting the second amount of mixture M2 into the second mold cavity 31b of the molding apparatus 30a in step 511, the pressure within the second mold cavity 31b changes rapidly, and the second pressure sensor 366b continuously senses the second pressure within the second mold cavity 31b. In some embodiments, the second amount of mixture M2 is injected into the second mold cavity 31b of the molding apparatus 30a from the second supply port 35b, and a second predetermined pressure is applied to the second amount of mixture M2. In some embodiments, the second amount of mixture M2 and the second gas G2 are placed within the second mold cavity 31b, and the second amount of mixture M2 expands and foams within the second mold cavity 31b.

[0111] In some embodiments, the process of injecting the second amount of mixture M2 into the second mold cavity 31 with the second predetermined pressure lasts less than 1 second. During the injection period or at the moment of completion of injection, the pressure in the second mold cavity 31b is sensed in real time by the second pressure sensing unit 366b to provide pressure information, so that the second pressure regulation system 36b can adjust the pressure in the second mold cavity 31b according to the pressure information, thereby maintaining the pressure in the second mold cavity 31b within a predetermined pressure range.

[0112] In some embodiments, a second amount of mixture M2 is injected from second feed port 35b into second mold cavity 31b of molding apparatus 30a, thereby increasing the second pressure within second mold cavity 31b containing second amount of mixture M2 to a fourth pressure. In some embodiments, the fourth pressure within second mold cavity 31b containing second amount of mixture M2 is greater than the second predetermined pressure. In some embodiments, the pressure within second mold cavity 31b of molding apparatus 30a is increased from the second predetermined pressure to a fourth pressure. In some embodiments, the third pressure is different from the fourth pressure.

[0113] In some embodiments, the method 500 includes a step 512 that includes sensing a fourth pressure in the second mold cavity 31b having the second amount of mixture M2 and injecting a fourth gas into the second mold cavity 31b or evacuating a portion of the gas G4 from the second mold cavity 31b until the second mold cavity 31b is sensed to have a fourth predetermined pressure, the third predetermined pressure being different from the fourth predetermined pressure.

[0114] In some embodiments, after the second amount of mixture M2 is injected into the second mold cavity 31b with the second predetermined pressure, the pressure within the second mold cavity 31b increases, and therefore setting a fourth predetermined pressure ensures that the second mold cavity 31b is maintained within a suitable pressure range. In some embodiments, once the second mold cavity 31b reaches the fourth predetermined pressure, the injection of the fourth gas into the second mold cavity 31b or the evacuation of a portion of the gas G4 from the second mold cavity 31b is stopped.

[0115] In some embodiments, in step 512, after injecting the fourth gas into the second mold cavity 31b, gas G4 is discharged from the second mold cavity 31b. In some embodiments, step 512 further includes foaming the second amount of mixture M2 in the second mold cavity 31b and discharging gas G4 from the second mold cavity 31b through the second pressure adjustment system 36b for less than 1 second while the second amount of mixture M2 is foaming in the second mold cavity 31b. Due to the discharge of gas G4, the second amount of mixture M2 in the second mold cavity 31b after the foaming process may have a lower density. In some embodiments, gas G4 is discharged from the second mold cavity 31b through junction 37 of the second pressure adjustment system 36b. In some embodiments, gas G4 is discharged from the second mold cavity 31b during or after the foaming process of the second amount of mixture M2 in the second mold cavity 31b. In some embodiments, the fourth pressure within second mold cavity 31b is reduced to a fourth predetermined pressure.

[0116] In some embodiments, when second pressure sensing unit 366b senses that the fourth pressure in second mold cavity 31b is higher than the fourth predetermined pressure, gas G4 in second mold cavity 31b is vented until the pressure in second mold cavity 31b falls within a predetermined pressure range. In some embodiments, this predetermined pressure range is between the second predetermined pressure and the fourth predetermined pressure. In some embodiments, second valve 365 is open, and a portion of gas G4 in second mold cavity 31b is vented through second gas conduit 362 of second pressure regulation system 36b.

[0117] 19, the method 500 includes a step 513 that includes disengaging the first outlet 21a from the second supply port 35b. In some embodiments, after injecting the second amount of mixture M2 into the second mold cavity 31b, the first discharge channel 20a is disengaged and moved away from the molding apparatus 30a. In some embodiments, the support apparatus 40 is transitioned to an unlocked state before the first outlet 21a is disengaged from the second supply port 35b.

[0118] In steps 501 to 513 above and the following processes, control system 60 automatically controls extrusion system 10, first discharge channel 20a, first and second mold cavities 31a and 31b, and support device 40 in real time. In some embodiments, control system 60 controls the movement of extrusion system 10 and first discharge channel 20a. In some embodiments, control system 60 controls the movement of molding device 30a. In some embodiments, control system 60 controls the injection of a first gas G1 into first mold cavity 31a and the discharge of a portion of the first gas G1 from first mold cavity 31a in response to a first pressure in first mold cavity 31a, and controls the injection of a second gas G2 into second mold cavity 31b and the discharge of a portion of the second gas G2 from second mold cavity 31b in response to a second pressure in second mold cavity 31b.

[0119] In the present disclosure, a method of injection molding is disclosed. In some embodiments, injection molding is performed by the method. The method includes several operations, and the description and illustration should not be considered a limitation on the sequence of operations. FIGS. 20A and 20B collectively show a flowchart of a method 600 of injection molding according to one embodiment of the present invention. Method 600 is not limited to the above-described embodiment. In some embodiments, injection molding method 600 uses injection molding system 200 as shown in FIG. 4 and described above.

[0120] In some embodiments, as shown in FIG. 21 , an injection molding method 600 includes step 601, which includes providing an extrusion system 10 configured to produce a mixture of a polymer material and a blowing agent, a first discharge channel 20a, and a second discharge channel 20b, wherein the first discharge channel 20a is capable of communicating with the extrusion system 10 and includes a first outlet 21a located distally from the extrusion system 10, and the second discharge channel 20b is capable of communicating with the extrusion system 10 and includes a second outlet 21b located distally from the extrusion system 10, and the first outlet 21a is capable of engaging with a first supply port 35a, and the second outlet 21b is capable of engaging with a second supply port 35b.

[0121] In some embodiments, the injection molding method 600 includes step 602, which includes providing a molding apparatus 30b, the molding apparatus 30b including a first mold cavity 31a and a second mold cavity 31b, a first supply port 35a in communication with the first mold cavity 31a, and a second supply port 35b in communication with the second mold cavity 31b.

[0122] In some embodiments, injection molding method 600 includes step 603, which includes sensing a first pressure within first mold cavity 31 a and injecting a first gas G1 into first mold cavity 31 a until first mold cavity 31 a is sensed to have a first predetermined pressure. In some embodiments, the process for performing step 603 is similar to the process for performing step 503, and a detailed description thereof will be omitted here for the sake of brevity.

[0123] In some embodiments, injection molding method 600 includes step 604, which includes sensing a second pressure in second mold cavity 31b and injecting a second gas G2 into second mold cavity 31b until second mold cavity 31b is sensed to have a second predetermined pressure, where the first predetermined pressure is different from the second predetermined pressure. In some embodiments, the process for performing step 604 is similar to the process for performing step 504, and a detailed description thereof will be omitted here for brevity. In some embodiments, steps 603 and 604 are performed simultaneously or separately.

[0124] 22, an injection molding method 600 includes step 605, which includes engaging the first outlet 21 a with the first supply port 35 a. In some embodiments, the process for performing step 605 is similar to the process for performing step 505, and a detailed description thereof will be omitted here for the sake of brevity.

[0125] In some embodiments, injection molding method 600 includes step 606, which includes engaging second outlet 21b with second supply port 35b. In some embodiments, the process for performing step 606 is similar to the process for performing step 510, and a detailed description thereof will be omitted here for the sake of brevity. In some embodiments, the engagement of first outlet 21a with first supply port 35a in step 605 and the engagement of second outlet 21b with second supply port 35b in step 606 occur simultaneously.

[0126] 23, an injection molding method 600 includes a step 607 that includes injecting a first amount of mixture M1 through a first outlet 21a and a first feed port 35a into a first mold cavity 31a with a first predetermined pressure. In some embodiments, the process for performing step 607 is similar to the process for performing step 506, and a detailed description thereof will be omitted here for the sake of brevity.

[0127] In some embodiments, injection molding method 600 includes step 608, which includes injecting a second quantity of mixture M2 through second outlet 21b and second feed port 35b into second mold cavity 31b with a second predetermined pressure. In some embodiments, the process for performing step 608 is similar to the process for performing step 511, and a detailed description thereof will be omitted here for the sake of brevity. In some embodiments, the injection of first quantity of mixture M1 and the injection of second quantity of mixture M2 occur simultaneously or separately.

[0128] In some embodiments, injection molding method 600 includes step 609, which includes sensing a third pressure within first mold cavity 31a having first quantity of mixture M1, and injecting a third gas into first mold cavity 31a or venting a portion of gas G3 from first mold cavity 31a until first mold cavity 31a is sensed to have a third predetermined pressure. In some embodiments, the process for performing step 609 is similar to the process for performing step 507, and a detailed description thereof will be omitted here for the sake of brevity.

[0129] In some embodiments, injection molding method 600 includes step 610, which includes sensing a fourth pressure in second mold cavity 31b having a second amount of mixture M2 and injecting a fourth gas into second mold cavity 31b or venting a portion of gas G4 from second mold cavity 31b until second mold cavity 31b is sensed to have a fourth predetermined pressure. In some embodiments, the third predetermined pressure is different from the fourth predetermined pressure. In some embodiments, the process for performing step 610 is similar to the process for performing step 512, and a detailed description thereof will be omitted here for brevity. In some embodiments, steps 609 and 610 are performed simultaneously or separately.

[0130] 24, an injection molding method 600 includes a step 611 that includes disengaging the first outlet 21 a from the first supply port 35 a and disengaging the second outlet 21 b from the second supply port 35 b. In some embodiments, disengaging the first outlet 21 a from the first supply port 35 a and disengaging the second outlet 21 b from the second supply port 35 b occurs simultaneously.

[0131] In the present disclosure, a method of injection molding is disclosed. The method includes several operations, and the description and illustration should not be considered a limitation on the sequence of operations. FIG. 25 is a flow chart illustrating a method 700 of injection molding according to one embodiment of the present invention. Method 700 is not limited to the above-described embodiment. In some embodiments, injection molding method 700 uses the above-described injection molding system 100 as shown in FIG. 1 or the above-described injection molding system 200 as shown in FIG. 4. In some embodiments, as shown in FIG. 25, method 700 includes the following steps:

[0132] Step 701 includes providing a molding apparatus including a first mold cavity and a second mold cavity, a first supply port in communication with the first mold cavity, and a second supply port in communication with the second mold cavity.

[0133] Step 702 includes sensing a first pressure within the first mold cavity and injecting a first gas into the first mold cavity until the first mold cavity is sensed to have a first predetermined pressure.

[0134] Step 703 includes sensing a second pressure in the second mold cavity and injecting a second gas into the second mold cavity until the second mold cavity is sensed to have a second predetermined pressure, the first predetermined pressure being different from the second predetermined pressure.

[0135] In the present disclosure, a method of injection molding is disclosed. The method includes several operations, and the description and illustration should not be considered a limitation on the sequence of operations. Figures 26A and 26B collectively show a flowchart of a method 800 of injection molding according to one embodiment of the present invention. Method 800 is not limited to the above-described embodiment. In some embodiments, injection molding method 800 uses the above-described injection molding system 100 as shown in Figure 1 or the above-described injection molding system 200 as shown in Figure 4. In some embodiments, as shown in Figures 26A and 26B, method 800 includes the following steps:

[0136] Step 801 includes providing an extrusion system configured to produce a mixture of a polymeric material and a blowing agent, and an outlet channel in communication with the extrusion system and including an outlet, the outlet being engageable with a first supply port and a second supply port.

[0137] Step 802 includes providing a molding apparatus including a first mold cavity and a second mold cavity, a first supply port in communication with the first mold cavity, and a second supply port in communication with the second mold cavity.

[0138] Step 803 includes engaging the outlet with a first supply port.

[0139] Step 804 includes injecting a first amount of the mixture through the outlet and a first feed port into a first mold cavity.

[0140] Step 805 includes disengaging the outlet from the first supply port.

[0141] Step 806 includes engaging the outlet with a second supply port.

[0142] Step 807 includes injecting a second amount of the mixture through the outlet and a second feed port into a second mold cavity.

[0143] Step 808 includes disengaging the outlet from the second supply port.

[0144] Step 809 includes sensing a first pressure within a first mold cavity having a first amount of the mixture and injecting a first gas into the first mold cavity or venting a portion of the gas from the first mold cavity until the first mold cavity is sensed to have a first predetermined pressure.

[0145] Step 810 includes sensing a second pressure in a second mold cavity having a second amount of the mixture, and injecting a second gas into the second mold cavity or venting a portion of the gas from the second mold cavity until the second mold cavity is sensed to have a second predetermined pressure, where the first predetermined pressure is different from the second predetermined pressure.

[0146] The foregoing outlines features of some embodiments so that those skilled in the art may better understand aspects of the present disclosure. Those skilled in the art will appreciate that this disclosure may readily serve as a basis for designing or modifying other processes and structures to carry out the same purposes and / or achieve the same advantages of the embodiments presented herein. Those skilled in the art will also recognize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations can be made in the present disclosure without departing from the spirit and scope of the present disclosure.

[0147] Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the processes, machines, manufacture, compositions of matter, means, methods, and steps described in the specification. As will be readily apparent to those skilled in the art from this disclosure, any now-existing or later-developed processes, machines, manufacture, compositions of matter, means, methods, or steps that perform substantially the same function or achieve substantially the same results 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, manufacture, compositions of matter, means, methods, and steps. [Explanation of symbols]

[0148] 10 Extrusion System 20 discharge channels 20a First discharge channel 21a 1st Exit 30a Molding equipment 36 Pressure Regulation System 100 Injection Molding System 120 fusion zone 121 Pressurized Cartridge 1211 Interior Space 122 first supply passage 123 First discharge passage 124 Pressing member 125 supply hopper 130 Mixing section 131 Mixed Cartridge 1311 Inner sidewall 132 Second supply passage 133 Second discharge passage 134 Mixing Rotor 1341 Columnar body 1342 Groove 140 Foaming Agent Supply Section 150 Injection part 151 Hollow Measuring Cartridge 1511 hollow interior space 152 Connecting Passage 153 Discharge member 154 Exit 161 first flow control element 162 Second flow control element 171 First Port 180 Monitoring Module 200 Injection Molding System 20 discharge channels 20a First discharge channel 20b Second outlet channel 21 Exit 21b Second Exit 31 mold hole 31a First mold cavity 31b Second mold cavity 311 Inner top wall 312 Inner sidewall 313 Inner bottom wall 32 Upper mold 33 Lower mold 34 Upper mold base 341 Opening 35 Supply Port 35a First supply port 35b Second supply port 36a First pressure regulation system 36b Secondary pressure regulation system 361 First Gas Pipe 362 Second Gas Pipe 363 Gas Supply Source 364 First Valve 365 Second Valve 366 Pressure sensor 366a First pressure sensing unit 366b Second pressure sensing unit 37 Junction 381 First Opening 382 Second Opening 383 First Pore 384 Second Pore 385 First Guidance Channel 386 Second Guidance Channel 41 First Element 42 Second Element 411 Long part 412 Arm part 60 Control System 61 Central Processor 62 sensors 63 Cable A arrow D1: Distance between the inner side wall of the pressing cartridge and the pressing member D2 Diameter of pressing member D3 Shortest distance between the inner sidewall of the hollow mixing cartridge and the mixing rotor D4 Diameter of mixing rotor G1 First Gas G2 Second Gas G3 Gas G4 Gas M1 First amount of mixture M2 Second amount of mixture X Second Direction Y third direction Z Primary Direction

Claims

1. 1. An injection molding method comprising: providing an extrusion system configured to produce a mixture of a polymeric material and a blowing agent, and a first discharge channel communicable with the extrusion system and including a first outlet disposed distally to the extrusion system; providing a molding apparatus including a first mold cavity and a second mold cavity separated from the first mold cavity, a first supply port in communication with the first mold cavity, and a second supply port in communication with the second mold cavity, the first outlet being engageable with the first supply port and the second supply port, respectively; sensing a first pressure within the first mold cavity and injecting a first gas into the first mold cavity until the first mold cavity is sensed to have a first predetermined pressure; sensing a second pressure within the second mold cavity and injecting a second gas into the second mold cavity until the second mold cavity is sensed to have a second predetermined pressure; injecting a first amount of the mixture through the first supply port into the first mold cavity at the first predetermined pressure; injecting a second amount of the mixture through the second feed port into the second mold cavity at the second predetermined pressure; foaming the first amount of the mixture in the first mold cavity; foaming the second amount of the mixture in the second mold cavity; sensing the first pressure within the first mold cavity having the first amount of the mixture and venting a portion of gas from the first mold cavity while foaming the first amount of the mixture within the first mold cavity until the first mold cavity is sensed to have a third predetermined pressure; sensing the second pressure within the second mold cavity having the second amount of the mixture and, while foaming the second amount of the mixture within the second mold cavity, venting a portion of the gas from the second mold cavity until the second mold cavity is sensed to have a fourth predetermined pressure; wherein the first predetermined pressure is different from the second predetermined pressure and the third predetermined pressure is different from the fourth predetermined pressure.

2. engaging the first outlet with the first supply port; disengaging the first outlet from the first supply port; moving the first discharge channel away from the first mold cavity toward the second mold cavity; engaging the first outlet with the second supply port; disengaging the first outlet from the second supply port; 2. The method of claim 1, further comprising: injecting said second amount of said mixture through said first outlet and said second feed port into said second mold cavity.

3. providing a second discharge channel in communication with the extrusion system and including a second outlet located distally from the extrusion system, the second outlet engageable with the second supply port; engaging the first outlet with the first supply port; engaging the second outlet with the second supply port; 10. The method of claim 1, wherein the second amount of the mixture is injected through the second outlet and the second feed port into the second mold cavity.

4. 1. An injection molding method comprising: providing an extrusion system configured to produce a mixture of a polymeric material and a blowing agent, and an outlet channel in communication with the extrusion system, the outlet channel including an outlet; providing a molding apparatus including a first mold cavity and a second mold cavity, a first supply port in communication with the first mold cavity, and a second supply port in communication with the second mold cavity, the outlets being engageable with the first supply port and the second supply port, respectively; engaging the outlet with the first supply port; injecting a first amount of the mixture through the outlet and the first feed port into the first mold cavity; disengaging the outlet from the first supply port; foaming the first amount of the mixture in the first mold cavity and engaging the outlet with the second supply port; injecting a second amount of the mixture through the outlet and the second feed port into the second mold cavity; disengaging the outlet from the second supply port; foaming the second amount of the mixture in the second mold cavity; sensing a first pressure within the first mold cavity having the first amount of the mixture, and injecting a first gas into the first mold cavity or venting a portion of gas from the first mold cavity while foaming the first amount of the mixture within the first mold cavity until the first mold cavity is sensed to have a first predetermined pressure; sensing a second pressure within the second mold cavity having the second amount of the mixture, and injecting a second gas into the second mold cavity or venting a portion of the gas from the second mold cavity while foaming the second amount of the mixture within the second mold cavity until the second mold cavity is sensed to have a second predetermined pressure; wherein the first predetermined pressure is different from the second predetermined pressure.

5. 5. The method of claim 4, wherein the first pressure in the first mold cavity is continuously sensed while the first amount of the mixture is being injected into the first mold cavity, and when the first pressure in the first mold cavity is sensed to be higher than the first predetermined pressure, the portion of the gas in the first mold cavity is vented from the first mold cavity.

6. injecting a third gas into the first mold cavity prior to injection of the first amount of the mixture into the first mold cavity; injecting a fourth gas into the second mold cavity prior to injection of the second amount of the mixture into the second mold cavity; The method of claim 4 further comprising:

7. 1. An injection molding system comprising: an extrusion system having a mixing section and an injection section, the mixing section configured to mix a polymeric material with a blowing agent to form a mixture, and the injection section receiving the mixture from the mixing section; a first discharge channel in communication with the ejection portion and including a first outlet configured to eject the mixture from the ejection portion; a molding device configured to receive the mixture from the first outlet; a pressure regulation system coupled to the molding apparatus; a control system for controlling the extrusion system, the first discharge channel, the molding apparatus, and the pressure adjustment system, wherein the molding apparatus includes a first mold cavity, a second mold cavity separated from the first mold cavity, a first supply port in communication with the first mold cavity and engageable with the first outlet, and a second supply port in communication with the second mold cavity and engageable with the first outlet; the mixing section includes a hollow mixing cartridge and a mixing rotor within the hollow mixing cartridge, the mixing rotor being unable to move in a direction parallel to a longitudinal axis of the hollow mixing cartridge; the pressure regulation system is configured to regulate pressure within the first mold cavity and the second mold cavity; the pressure regulation system includes a first pressure sensing unit configured to sense a first pressure in the first mold cavity in real time, and a second pressure sensing unit configured to sense a second pressure in the second mold cavity in real time; The control system includes: a control circuit configured to control an operation of injecting a first gas into the first mold cavity and discharging a portion of the gas from the first mold cavity in response to the first pressure in the first mold cavity; an injection molding system configured to control, in response to the second pressure in the second mold cavity, an operation of injecting a second gas into the second mold cavity and evacuating a portion of the gas from the second mold cavity.

8. 8. The injection molding system of claim 7, wherein the ratio of the shortest distance between the inner sidewall of the hollow mixing cartridge and the mixing rotor to the diameter of the mixing rotor is in the range of 1:1500 to 1:4500.

9. 8. The injection molding system of claim 7, further comprising a second discharge channel capable of communicating with the injection section and including a second outlet configured to discharge the mixture from the injection section, wherein the first discharge channel and the second discharge channel have the same or different widths from each other.

10. The pressure regulation system comprises: a first gas conduit connected to the molding apparatus and in communication with the first mold cavity; a first valve disposed in the first gas conduit and configured to control gas injection from a gas source through the first gas conduit into the first mold cavity; a second gas conduit connected to the molding apparatus and in communication with the second mold cavity; and a second valve disposed in the second gas conduit and configured to control the discharge of gas out of the second mold cavity; 8. The injection molding system of claim 7, comprising:

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