Injection molding system and method

Abstract

To provide an injection molding method.SOLUTION: There is provided an injection molding method, comprising the following steps of: preparing a molding device in which the molding device includes a first mold, a second mold over the first mold, and a middle mold being between the first mold and the second mold; disposing a first component on the second mold; engaging the middle mold with the first mold and the second mold after the first component is disposed on the second mold to form a mold cavity; injecting a polymeric material into the mold cavity to surround the first component; and obtaining an article formed by the polymeric material and the first component.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims priority to U.S. Provisional Patent Application No. 63 / 550,631, filed February 7, 2024, and U.S. Patent Application No. 18 / 822,509, filed September 3, 2024, both of which are incorporated by reference in their entireties.

[0002] [Technical field] FIELD OF THE DISCLOSURE The present disclosure relates to injection molding systems and methods, and more particularly to injection molding systems and methods for forming articles including multiple components. [Background technology]

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

[0004] However, there is a need for improvements in the formation of multiple articles (e.g., pairs) that include multiple components, each with different physical or functional properties. Accordingly, there is a need for improved injection molding system structures and methods for producing foamed articles. Summary of the Invention

[0005] The present disclosure discloses an injection molding system and method.

[0006] According to one embodiment of the present disclosure, there is provided an injection molding method, comprising the steps of: providing a molding apparatus including a first mold, a second mold above the first mold, and an intermediate mold between the first and second molds; placing a first component in the second mold; after placing the first component in the second mold, engaging the intermediate mold with the first and second molds to form a mold cavity; injecting a polymeric material into the mold cavity to surround the first component; and obtaining an article formed from the polymeric material and the first component.

[0007] According to one embodiment of the present disclosure, there is provided an injection molding system. The injection molding system includes a molding apparatus including a first mold, a second mold above the first mold, and an intermediate mold between the first and second molds. The second mold includes a support unit that is extendable and retractable relative to the second mold and faces the first mold. The intermediate mold includes an outer intermediate mold and an inner intermediate mold that is surrounded by the outer intermediate mold and is movable relative to the outer intermediate mold. [Brief explanation of the drawings]

[0008] Aspects of the present disclosure will be best understood from the following detailed description when taken in conjunction with the accompanying drawings, in which: Figure 1 is a block diagram of a semiconductor device according to an embodiment of the present invention;

[0009] [Figure 1] FIG. 1 is a schematic perspective view of an injection molding system according to some embodiments of the present disclosure. [Figure 2] FIG. 1 is a schematic perspective view of a molding apparatus in a closed configuration, according to some embodiments of the present disclosure. [Figure 3A] FIG. 10 illustrates a bottom view of an upper mold according to some embodiments of the present disclosure. [Figure 3B] FIG. 1 illustrates a front perspective view of an upper mold according to some embodiments of the present disclosure. [Figure 4A] FIG. 1 illustrates a top view of a molding apparatus in an open configuration according to some embodiments of the present disclosure. [Figure 4B] FIG. 1 illustrates a front perspective view of a molding apparatus in an open configuration according to some embodiments of the present disclosure. [Figure 5] FIG. 1 is a schematic top view of an injection molding system according to some embodiments of the present disclosure. [Figure 6] 1 is a flowchart illustrating an injection molding method according to some embodiments of the present disclosure. [Figure 7] FIG. 10 is a top view of a core component positioned in an upper mold according to some embodiments of the present disclosure. [Figure 8A] FIG. 1 illustrates a bottom view of an upper mold in which a core component is constructed (or placed) according to some embodiments of the present disclosure. [Figure 8B] FIG. 1 illustrates a front perspective view of an upper mold in which a core component is constructed (or placed) according to some embodiments of the present disclosure. [Figure 9] FIG. 10 is a top view of a bottom component positioned in a lower mold according to some embodiments of the present disclosure. [Figure 10A] 1 illustrates a top view of a molding apparatus in which a bottom component is configured (or arranged) according to some embodiments of the present disclosure. [Figure 10B] 1 illustrates a front perspective view of a molding apparatus in which a bottom component is configured (or arranged) according to some embodiments of the present disclosure. [Figure 11A] 1 illustrates a top view of a molding apparatus in which a bottom component is configured (or arranged) according to some embodiments of the present disclosure. [Figure 11B] 1 illustrates a front perspective view of a molding apparatus in which a bottom component is configured (or arranged) according to some embodiments of the present disclosure. [Figure 12A] 1 illustrates a perspective view of a closing molding apparatus according to some embodiments of the present disclosure. [Figure 12B] 1 illustrates a top view of a closing molding apparatus according to some embodiments of the present disclosure. [Figure 12C] FIG. 1 illustrates a front perspective view of a closing molding apparatus according to some embodiments of the present disclosure. [Figure 13A]FIG. 1 illustrates a perspective view of a molding apparatus in a closed configuration according to some embodiments of the present disclosure. [Figure 13B] FIG. 1 illustrates a front perspective view of a molding apparatus in a closed configuration according to some embodiments of the present disclosure. [Figure 13C] FIG. 1 illustrates a side perspective view of a molding apparatus in a closed configuration according to some embodiments of the present disclosure. [Figure 14A] FIG. 1 illustrates a front perspective view of a molding apparatus in which a polymeric material is injected into a mold cavity to form an article, according to some embodiments of the present disclosure. [Figure 14B] FIG. 1 illustrates a side perspective view of a molding apparatus in which a polymeric material is injected into a mold cavity to form an article, according to some embodiments of the present disclosure. [Figure 15] 1 shows a perspective view of an article according to some embodiments of the present disclosure. [Figure 16] FIG. 1 illustrates a side perspective view of a molding apparatus including an inner mold according to some embodiments of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0010] The following disclosure provides many different embodiments or examples for implementing different features of the provided subject matter. Below, specific examples of components and arrangements are described to simplify the disclosure. It should be understood that these are merely examples and are not intended to be limiting. For example, in the following description, a reference to forming a first feature above or on a second feature may include an embodiment in which the first and second features are formed in direct contact with each other, or an embodiment in which an additional feature is formed between the first and second features such that the first and second features are not in direct contact with each other. Additionally, the disclosure may repeat reference numerals and / or letters in various examples. This repetition is for the purposes of brevity and clarity and does not, in itself, indicate a relationship between the various embodiments and / or configurations described.

[0011] Additionally, spatially relative terms such as "bottom," "lower," "bottom," "upper," "top," and the like may be used herein for ease of description to describe the relationship of one element or feature to another element(s) or feature(s), as shown in the figures. Spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

[0012] 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 specified, all numerical ranges, amounts, values, and percentages relating to amounts of materials, times, temperatures, operating conditions, ratios of amounts, and the like, disclosed herein should be understood to be modified in all instances by the term "about." Accordingly, unless indicated to the contrary, the numerical parameters set forth in the present disclosure and 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 are inclusive of the endpoints unless otherwise specified.

[0013] 1 is a schematic perspective view of an injection molding system 100 according to some embodiments of the present disclosure. Injection molding system 100 includes a molding apparatus 10 in an open configuration. Injection molding system 100 further includes a position control mechanism 20 configured to control molding apparatus 10 in either the open configuration or the closed configuration shown in FIG. 2. In some embodiments, position control mechanism 20 is disposed adjacent to molding apparatus 10.

[0014] In some embodiments, the molding apparatus 10 includes an upper mold 11, a lower mold 13, an outer intermediate mold (or side mold) 15 disposed between the upper mold 11 and the lower mold 13, and a plurality of mold cavities 19 for forming the article 30, defined by the upper mold 11, the lower mold 13, and the outer intermediate mold 15. For simplicity and clarity, two mold cavities 19a, 19b are illustrated, but it should be understood that any suitable number of mold cavities 19 may be configured in the molding apparatus 10. In some embodiments, the upper mold 11 corresponds in some configurations, such as size, shape, etc., to the lower mold 13. The upper mold 11 can be positioned and engaged with the outer intermediate mold 15. In some embodiments, preparing the molding apparatus 10 includes transporting the outer intermediate mold 15 toward the lower mold 13 and then positioning the upper mold 11 above the outer intermediate mold 15, with these movements controlled by a position control mechanism 20. In some embodiments, the upper mold 11 is aligned with the lower mold 13. In some embodiments, the upper mold 11 is positioned above the outer intermediate mold 15 and is movable and engageable with respect to the outer intermediate mold 15, and the outer intermediate mold 15 is positioned above the lower mold 13 and is movable and engageable with respect to the lower mold 13.

[0015] In some embodiments, upper mold 11 includes multiple feed ports 12. In some embodiments, each feed port 12 has an opening 121 extending through upper mold 11 and located on the top surface of upper mold 11. In some embodiments, feed ports 12 can communicate with mold cavity 19 when molding apparatus 10 is in a closed configuration.

[0016] In some embodiments, the mold cavities 19 are accessible through feed ports 12. For simplicity and clarity, six feed ports 12 are shown on the top surface of the upper mold 11 in FIG. 2 . However, as can be appreciated, any suitable number of feed ports 12 may be configured on the upper mold 11. In some embodiments, instead of configuring the feed ports 12 on the upper mold 11, the feed ports 12 are located on the lower mold 13 or the outer intermediate mold 15 to access the mold cavities 19. In some embodiments, the feed ports 12 may be configured in any other suitable location as long as they are capable of communicating with the mold cavities 19. For example, some of the feed ports 12 are located on the upper mold 11, and the remaining feed ports 12 are located on the lower mold 13 and / or the outer intermediate mold 15.

[0017] In some embodiments, injection molding system 100 further includes an extrusion system (not shown) and a discharge channel (not shown) disposed above molding apparatus 10. In some embodiments, the extrusion system is configured to produce a mixture of polymeric material and a blowing agent. In some embodiments, the discharge channel is in communication with the extrusion system and includes an outlet disposed remotely from the extrusion system and configured to discharge the mixture into molding apparatus 10 through feed opening 12. In some embodiments, molding apparatus 10 is configured to receive the mixture from the outlet of the discharge channel. In some embodiments, feed opening 12 is in communication with mold cavity 19 and is engageable with the outlet.

[0018] In an embodiment of the present disclosure, a side perspective view of the components of molding apparatus 10 is taken along line II' in FIG. 2, and a front perspective view of the components of molding apparatus 10 is taken along line II' in FIG. 2.

[0019] 3A and 3B show bottom and front perspective views, respectively, of an upper mold 11 according to some embodiments of the present disclosure. The upper mold 11 has a bottom surface 111 and a top surface 112. When the molding apparatus 10 is in a closed configuration, the bottom surface 111 of the upper mold 11 faces the outer intermediate mold 15. Two seal rings 16 are disposed on the bottom surface 111 of the upper mold 11. The two seal rings 16 include a first seal ring 16a and a second seal ring 16b that are separated from each other. In some embodiments, the number of seal rings 16 is the same as the number of mold cavities 19. Each seal ring 16 corresponds to a respective mold cavity 19.

[0020] In some embodiments, the upper mold 11 has multiple supply ports 12. In some embodiments, the supply ports 12 include one or more first supply ports 12a and one or more second supply ports 12b. As shown in FIG. 3A from a bottom view, the first supply ports 12a are disposed within the first seal ring 16a, and the second supply ports 12b are disposed within the second seal ring 16b. Each first supply port 12a has a first opening (or first sprue) 121a formed in the upper mold 11. Each first opening 121a is configured to extend through the upper mold 11 and can communicate with the first mold cavity 19a when the molding apparatus 10 is in a closed configuration. Each second supply port 12b has a second opening (or second sprue) 121b formed in the upper mold 11. The second openings 121b are configured to extend through the upper mold 11 and can communicate with the second mold cavity 19b when the molding apparatus 10 is in a closed configuration. In some embodiments, the number of first supply openings 12a is equal to the number of second supply openings 12b. In some embodiments, the first openings 121a are arranged in a first line (not shown) with the same pitch, and the second openings 121b are arranged in a second line (not shown) with the same pitch. In some embodiments, the second line is parallel to the first line. While the embodiment of FIG. 3A shows three first openings 121a and three second openings 121b, this is not intended to limit the number of openings 121 in the upper mold 11.

[0021] In some embodiments, the upper mold 11 has a plurality of support units 14. One end of each support unit 14 is within the upper mold 11, and the other end of each support unit 14 protrudes from the bottom surface 111 of the upper mold 11. In some embodiments, the support units 14 are nails, screws, or posts. In some embodiments, the support units 14 include one or more first support units 14a and one or more second support units 14b. As shown in FIG. 3A , the protruding portion of the first support unit 14a is disposed within the first seal ring 16a when viewed from the bottom, and the protruding portion of the second support unit 14b is disposed within the second seal ring 16b when viewed from the bottom. In some embodiments, the number of first support units 14a is equal to the number of second support units 14b. In some embodiments, the first support units 14a are arranged in a third straight line (not shown) at the same pitch, and the second support units 14b are arranged in a fourth straight line (not shown) at the same pitch. In some embodiments, the fourth line is parallel to the third line and / or the first and second lines of the opening 121. Although the embodiment of FIG. 3A shows two first support units 14a and two second support units 14b, this is not intended to limit the number of support units 14 in the upper mold 11.

[0022] In some embodiments, the third and fourth lines of the support units 14 overlap with the first and second lines of the openings 121. In some embodiments, the third and fourth lines of the support units 14 do not overlap with the first and second lines of the openings 121. In some embodiments, the number of support units 14 is less than the number of supply ports 12. In some embodiments, the number of support units 14 is the same as the number of supply ports 12. In some embodiments, each support unit 14 is disposed between the openings 121 of two adjacent supply ports 12 when viewed from the bottom. For example, as shown in FIG. 3A , each first support unit 14a is disposed between two adjacent first openings 121a, and each second support unit 14b is disposed between two adjacent second openings 121b.

[0023] 4A and 4B show top and front perspective views, respectively, of molding apparatus 10 in an open configuration, according to some embodiments of the present disclosure. Figures 4A and 4B show outer intermediate mold 15 and lower mold 13 of molding apparatus 10.

[0024] The outer intermediate mold 15 includes a first portion 151 and a second portion 152. The first portion 151 and the first slider 171 are adjacent to and engageable with each other, and the second portion 152 and the second slider 172 are adjacent to and engageable with each other. In some embodiments, the first portion 151 and the second portion 152 are movable and detachable, and the first slider 171 and the second slider 172 are movable and detachable. In some embodiments, the second portion 152 and the first portion 151 are movable relative to each other, and the first slider 171 and the second slider 172 are movable relative to each other. In some embodiments, the first slider 171 and the second slider 172 are the inner intermediate mold 17 of the molding apparatus 10.

[0025] In some embodiments, the lower mold 13 includes a first portion 131, a second portion 132, and a third portion 133. The first portion 131 and the second portion 132 are disposed on two opposite sides of the third portion 133. In some embodiments, the first recess 115a is formed in the first portion 131, and the second recess 115b is formed in the second portion 132. The first slider 171 and the second slider 172 are disposed above the third portion 133 and between the first portion 131 and the second portion 132. In some embodiments, the first portion 151 and the first slider 171 of the outer intermediate mold 15 are disposed above the first portion 131 of the lower mold 13, and the second portion 152 and the second slider 172 of the outer intermediate mold 15 are disposed above the second portion 132 of the lower mold 13. In some embodiments, the first slider 171 is at least partially surrounded by the first portion 151 of the outer intermediate mold 15 , and the second slider 172 is at least partially surrounded by the second portion 152 of the outer intermediate mold 15 .

[0026] In some embodiments, when molding apparatus 10 is in a closed configuration, upper mold 11, first portion 131 of lower mold 13, first portion 151 of outer intermediate mold 15, and first slider 171 define a first mold cavity 19a, and upper mold 11, second portion 132 of lower mold 13, second portion 152 of outer intermediate mold 15, and second slider 172 define a second mold cavity 19b. In some embodiments, when molding apparatus 10 is in a closed configuration, first portion 151 of outer intermediate mold 15 and first slider 171 are attached and engage with each other to seal first mold cavity 19a. Similarly, when molding apparatus 10 is in a closed configuration, second portion 152 of outer intermediate mold 15 and second slider 172 are attached and engage with each other to seal second mold cavity 19b.

[0027] In some embodiments, when the molding apparatus 10 is in the open configuration, the outer intermediate mold 15 and the inner intermediate mold 17 are separated from one another. For example, when the molding apparatus 10 is in the open configuration, the first portion 151 and the first slider 171 of the outer intermediate mold 15 are separated from one another, allowing the article 30a formed in the first mold cavity 19a to be easily removed from the first mold cavity 19a. Similarly, when the molding apparatus 10 is in the open configuration, the second portion 152 and the second slider 172 of the outer intermediate mold 15 are separated from one another, allowing the article 30b formed in the second mold cavity 19b to be easily removed from the second mold cavity 19b. When the molding apparatus 10 is in the open configuration, the first recess 115a and the second recess 115b of the lower mold 13 are exposed. In some embodiments, the article 30 is removed from the molding apparatus 10 by a human or a robotic arm (not shown).

[0028] In some embodiments, when molding apparatus 10 is in the open configuration, there is a gap G1 between first portion 151 and second portion 152. In some embodiments, first portion 151 extends first mold cavity 19a away from first slider 171, and second portion 152 extends second mold cavity 19b away from second slider 172. In some embodiments, first portion 151 and first slider 171 extend first mold cavity 19a away from each other, and second portion 152 and second slider 172 extend second mold cavity 19b away from each other. In some embodiments, mold cavity 19a and mold cavity 19b are extended when molding apparatus 10 is in the open configuration.

[0029] In some embodiments, when molding apparatus 10 is in the open configuration, there is a gap G3 between first slider 171 and second slider 172. In some embodiments, gap G3 is smaller than gap G1. In some embodiments, there is no gap G3 between first slider 171 and second slider 172, i.e., first slider 171 contacts second slider 172.

[0030] In some embodiments, the movement of the upper mold 11 and the outer intermediate mold 15 is controlled by the position control mechanism 20 of FIG. 1 . In some embodiments, the position control mechanism 20 is connected to or attached to the upper mold 11 and the outer intermediate mold 15. In some embodiments, the upper mold 11 is movable toward the outer intermediate mold 15 and the lower mold 13 by the position control mechanism 20. In some embodiments, the position control mechanism 20 drives or operates the upper mold 11 away from the outer intermediate mold 15 so that the molding apparatus 10 is in an open configuration. As can be appreciated, the maximum amount of movement of the upper mold 11 is limited by the position control mechanism 20. In some embodiments, the position control mechanism 20 is configured to move the outer intermediate mold 15 above the lower mold 13 and position the upper mold 11 above the outer intermediate mold 15 to engage the upper mold 11 and the lower mold 13.

[0031] In some embodiments, the position control mechanism 20 is configured to drive or actuate the upper mold 11 to move upward when the molding apparatus 10 is in the open configuration. In some embodiments, the position control mechanism 20 is configured to move the upper mold 11 and the outer intermediate mold 15 relative to each other. In some embodiments, the position control mechanism 20 is used to separate the first portion 151 and the second portion 152 of the outer intermediate mold 15 when the molding apparatus 10 is in the open configuration. In some embodiments, the position control mechanism 20 is configured to move the first portion 151 of the outer intermediate mold 15 and the first slider 171 relative to each other, and to move the second portion 152 of the outer intermediate mold 15 and the second slider 172 relative to each other.

[0032] FIG. 5 is a schematic top view of an injection molding system according to some embodiments of the present disclosure. In FIG. 5, the injection molding system includes a first carrier 101 and a second carrier 102 disposed adjacent to the first carrier 101. In some embodiments, the first carrier 101 and the second carrier 102 are each toroidal. In some embodiments, the first carrier 101 is rotatable around a first center C1 along a first direction R1, and the second carrier 102 is rotatable around a second center C2 along a second direction R2. In some embodiments, each of the first carrier 101 and the second carrier 102 is rotatable clockwise or counterclockwise. The first carrier 101 and the second carrier 102 rotate in the first direction R1 and the second direction R2, respectively. In some embodiments, the first carrier 101 and the second carrier 102 rotate at predetermined intervals. In some embodiments, the first carrier 101 and the second carrier 102 rotate independently or simultaneously. In some embodiments, the first direction R1 and the second direction R2 may be the same or different from each other. In some embodiments, the first carrier 101 and the second carrier 102 are automatically operated and controlled. In some embodiments, the first carrier 101 and the second carrier 102 can communicate with each other via any suitable communication protocol, such as a programmable logic control (PLC) protocol.

[0033] In some embodiments, the multiple molding stations 200 are configured on the first carrier 101 and the second carrier 102. In some embodiments, the molding stations 200 include multiple first molding stations 200a configured on the first carrier 101 and multiple second molding stations 200b configured on the second carrier 102. In some embodiments, the molding apparatus 10 including the first upper mold 11a, the outer intermediate mold 15, and the lower mold 13 is arranged in the first molding station 200a, and the molding apparatus 10 including the second upper mold 11b, the outer intermediate mold 15, and the lower mold 13 is arranged in the second molding station 200b. In some embodiments, the first upper mold 11a and the second upper mold 11b have different configurations. In some embodiments, the outer intermediate mold 15 and the lower mold 13 of the first molding station 200a and the outer intermediate mold 15 and the lower mold 13 of the second molding station 200b have the same configuration.

[0034] 5, the injection molding system further includes a first injector 104 adjacent to the first carrier 101 and a second injector 105 adjacent to the second carrier 102. The first injector 104 is disposed above one of the plurality of first molding stations 200a and is configured to inject a first polymeric material into a mold cavity 19 defined by the lower mold 13, outer intermediate mold 15, and first upper mold 11a of the one of the plurality of first molding stations 200a. Similarly, the second injector 105 is disposed above one of the plurality of second molding stations 200b and is configured to inject a second polymeric material into a mold cavity 19 defined by the lower mold 13, outer intermediate mold 15, and second upper mold 11b of the one of the plurality of second molding stations 200b. In some embodiments, the first polymeric material may flow from a first injector 104 through a first supply port 12a and a second supply port 12b of the first upper mold 11a into the first mold cavity 19a and the second mold cavity 19b, and the second polymeric material may flow from a second injector 105 through a first supply port 12a and a second supply port 12b of the second upper mold 11b into the first mold cavity 19a and the second mold cavity 19b.

[0035] In some embodiments, the injection molding system 100 includes a bridging mechanism 103 disposed between the first carrier 101 and the second carrier 102. The bridging mechanism 103 connects the first carrier 101 and the second carrier 102 and is configured to transport the lower mold 13 and the outer intermediate mold 15 from the first carrier 101 to the second carrier 102 or from the second carrier 102 to the first carrier 101. In some embodiments, the bridging mechanism 103 is detachable from the injection molding system of FIG. 5. The bridging mechanism 103 is operable independently of the first carrier 101 and the second carrier 102.

[0036] FIG. 6 is a flowchart illustrating an injection molding method 300 according to some embodiments of the present disclosure. The injection molding method 300 includes steps S310-S360, and the description and illustration do not limit the order of steps S310-S360. FIGS. 7-16 are schematic top views, perspective views, or cross-sectional views of each stage of the injection molding method 300. In some embodiments, the steps of the injection molding method 300 can be repeated and performed automatically. In some embodiments, the injection molding method 300 is performed by the injection molding system 100 of FIG. 1 and the injection molding system of FIG. 5.

[0037] In step S310, a molding apparatus 10 is provided, including an upper mold 11, a lower mold 13, and an outer intermediate mold 15 disposed between the upper mold 11 and the lower mold 13. In step S320, a core component 32 is disposed in the upper mold 11. In step S330, a bottom component 34 is disposed in the lower mold 13. In step S340, the outer intermediate mold 15 is engaged with the upper mold 11 and the lower mold 13 to form a mold cavity 19. In step S350, a polymeric material is injected into the mold cavity 19 so as to adhere to the bottom component and surround the core component. In step S360, an article including the polymeric material, the core component, and the bottom component is obtained from the mold cavity 19. In some embodiments, the order of steps S320 and S330 can be reversed. The core component 32 and the bottom component 34 are described below.

[0038] Various embodiments are provided below to illustrate the concepts and injection molding method 300 of the present disclosure. However, the present disclosure is not intended to be limited to specific embodiments. Furthermore, elements, conditions, or parameters shown in different embodiments can be combined or modified to form different combinations of embodiments, as long as the elements, parameters, or conditions used are not inconsistent. For convenience of description, reference numerals having similar or identical functions and characteristics are repeatedly used in different embodiments and figures.

[0039] As described above, molding apparatus 10 further includes inner intermediate mold 17, which includes first slider 171 and second slider 172. In some embodiments, molding apparatus 10 includes two or more mold cavities 19. In some embodiments, first mold cavity 19a is defined by upper mold 11, lower mold 13, first slider 171, and first portion 151 of outer intermediate mold 15, and second mold cavity 19b is defined by upper mold 11, lower mold 13, second slider 172, and second portion 152 of outer intermediate mold 15.

[0040] 7 is a top view of a core component 32 placed in an upper mold 11 according to some embodiments of the present disclosure. In some embodiments, the core component 32 has one or more openings 321. The core component 32 includes a first core component 32a and a second core component 32b. In some embodiments, the core component 32 is a pair of insoles, a pair of air-cushion insoles, a pair of foot pads, or any other suitable component of footwear. In some embodiments, the first core component 32a is a left-foot insole, and the second core component 32b is a right-foot insole. In some embodiments, the number of openings 321a in the first core component 32a is equal to the number of openings 321b in the second core component 32b.

[0041] In some embodiments, the apertures 321a are arranged in a fifth line (not shown) with the same pitch, and the apertures 321b are arranged in a sixth line (not shown) with the same pitch. In some embodiments, the fifth line is parallel to the sixth line. While the embodiment of FIG. 7 shows three apertures 321a and three apertures 321b, this is not intended to limit the number of apertures 321 in the core component 32.

[0042] In some embodiments, the core component 32 comprises a polymeric material such as ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethane (TPU), or thermoplastic polyester elastomer (TPEE). In some embodiments, the core component 32 is a non-foam component. In some embodiments, the core component 32 comprises a recyclable material. Alternatively, in some embodiments, the core component 32 is a foam component. In some embodiments, the foam component comprises a polymeric material and a blowing agent. In some embodiments, the rigidity of the non-foam component is greater than the rigidity of the foam component.

[0043] 8A and 8B show bottom and front perspective views, respectively, of an upper mold 11 on which core components 32 are configured (or arranged), according to some embodiments of the present disclosure. In some embodiments, a first core component 32a is secured to the upper mold 11 by a first support unit 14a, and a second core component 32b is secured to the upper mold 11 by a second support unit 14b. In some embodiments, the support units 14 do not penetrate the core components 32. In some embodiments, the support units 14 penetrate the core components 32. In some embodiments, each support unit 14 is at least partially surrounded by the core components 32.

[0044] In some embodiments, when the core component 32 is fixed by the support unit 14, there is a gap G2 between the upper mold 11 and the core component 32. In some embodiments, the upper mold 11 further includes an inner core, and there is a gap G2 between the inner core of the upper mold 11 and the core component 32. In some embodiments, when the core component 32 is placed in the upper mold 11, the opening 321 of the core component 32 overlaps with the opening 121 of the upper mold 11. For example, when the first core component 32a is placed in the upper mold 11 by the first support unit 14a, the opening 321a of the first core component 32a may fully or partially overlap with the opening 121a of the upper mold 11 in a bottom view. Similarly, when the second core component 32b is placed in the upper mold 11 by the second support unit 14b, the opening 321b of the second core component 32b may fully or partially overlap with the opening 121b of the upper mold 11 in a bottom view. In some embodiments, the opening 321 in the core component 32 does not overlap with the opening 121 in the upper mold 11. In some embodiments, the core component 32 is placed in the upper mold 11 by a human or a robotic arm (not shown).

[0045] 9 is a top view of bottom components 34 positioned in lower mold 13 according to some embodiments of the present disclosure. In some embodiments, bottom component 34 includes first bottom component 34a and second bottom component 34b. In some embodiments, bottom component 34 is a pair of outsoles, a pair of foot pads, or any other suitable component of footwear. In some embodiments, first bottom component 34a is a left foot outsole and second bottom component 34b is a right foot outsole.

[0046] In some embodiments, the bottom component 34 comprises a polymeric material such as EVA, SEBS, TPU, or TPEE. In some embodiments, the bottom component 34 comprises a recyclable material. In some embodiments, the bottom component 34 is non-foamed or foamed. In some embodiments, the bottom component 34 further comprises a foaming agent. In some embodiments, the foaming agent may be any type of chemical or physical foaming agent known to those skilled in the art. In some embodiments, the foaming agent is a supercritical fluid. The supercritical fluid may include an inert gas such as carbon dioxide or nitrogen in a supercritical state. In some embodiments, the bottom component 34 is made of a molding material including a polymeric material and a foaming agent.

[0047] In some embodiments, the material of the core component 32 shown in FIG. 7 is different from the material of the base component 34. In some embodiments, the thickness of the core component 32 is less than the thickness of the base component 34. In some embodiments, the area of the core component 32 is less than the area of the base component 34. For example, the area of the first core component 32a is less than the area of the first bottom component 34a. In some embodiments, the core component 32 and the bottom component 34 have similar profiles, and the perimeter of the core component 32 is less than the perimeter of the bottom component 34.

[0048] 10A and 10B show a top view and a front perspective view, respectively, of a molding apparatus 10 on which a bottom component 34 is configured (or positioned), according to some embodiments of the present disclosure. Figures 10A and 10B show the outer intermediate mold 15, sliders 171, 172, and bottom mold 13 of the molding apparatus 10, with the outer intermediate mold 15 in an open configuration. The bottom component 34 is positioned on the bottom mold 13.

[0049] In some embodiments, when the outer intermediate mold 15 is opened, the first portion 151 and the second portion 152 of the outer intermediate mold 15 move away from each other, forming a gap G1 between the first portion 151 and the second portion 152. In some embodiments, after the first portion 151 moves away from the second portion 152, the first slider 171 and the second slider 172 move closer to each other, which allows the bottom component 34 to be easily attached to the lower mold 13.

[0050] In some embodiments, the first bottom component 34a is disposed in the first recess 115a, and the second bottom component 34b is disposed in the second recess 115b. In some embodiments, the first bottom component 34a is contoured to match the shape of the first recess 115a, and the second bottom component 34b is contoured to match the shape of the second recess 115b. For example, the first recess 115a is completely filled with the first bottom component 34a, and the second recess 115b is completely filled with the second bottom component 34b. In some embodiments, the contour of the first bottom component 34a is smaller than the shape of the first recess 115a, and the contour of the second bottom component 34b is smaller than the shape of the second recess 115b. For example, the first bottom component 34a does not completely fill the first recess 115a, and the second bottom component 34b does not completely fill the second recess 115b. In some embodiments, the bottom component 34 is placed into the lower mold 13 by a human or a robotic arm (not shown).

[0051] 11A and 11B show a top view and a front perspective view, respectively, of a molding apparatus 10 in which a bottom component 34 is configured (or arranged), according to some embodiments of the present disclosure. 11A and 11B show the outer intermediate mold 15, sliders 171 / 172, and bottom mold 13 of the molding apparatus 10, with the outer intermediate mold 15 in a closed configuration.

[0052] In some embodiments, after the bottom component 34 is placed in the lower mold 13, when the outer intermediate mold 15 is closed by moving the first portion 151 and the second portion 152 of the outer intermediate mold 15 into engagement, the gap G1 between the first portion 151 and the second portion 152 decreases. In some embodiments, after the first portion 151 engages the second portion 152, the first slider 171 moves to engage the first portion 151 and the second slider 172 moves to engage the second portion 152, and the first slider 171 and the second slider 172 move away from each other such that the gap G3 increases. In some embodiments, when the outer intermediate mold 15 is in the closed configuration, only a portion of the third portion 133 of the lower mold 13 is exposed from a top view. For example, the third portion 133 is exposed from the gap G3 between the first slider 171 and the second slider 172. In some embodiments, when the outer intermediate mold 15 is in the closed configuration, the gap G1 is less than or equal to the gap G3.

[0053] In some embodiments, when the outer intermediate mold 15 is in a closed configuration, the bottom of the first mold cavity 19a is defined by the first bottom component 34a, and the sides of the first mold cavity 19a are defined by the engaged first portion 151 and engaged first slider 171 of the outer intermediate mold 15. Similarly, the bottom of the second mold cavity 19b is defined by the second bottom component 34b, and the sides of the second mold cavity 19b are defined by the engaged second portion 152 and engaged second slider 172 of the outer intermediate mold 15.

[0054] In some embodiments, the movement of first portion 151 and second portion 152 is controlled by position control mechanism 20, and gap G1 is also controlled by position control mechanism 20. In some embodiments, when first portion 151 and second portion 152 move, first slider 171 and second slider 172 can move accordingly. In some embodiments, the small movements of first slider 171 and second slider 172 are controlled by position control mechanism 20, and gap G3 is also controlled by position control mechanism 20.

[0055] 12A, 12B, and 12C show a perspective view, a top view, and a front perspective view, respectively, of a closable molding apparatus 10 according to some embodiments of the present disclosure.

[0056] In some embodiments, after the bottom component 34 is placed in the lower mold 13, the position control mechanism 20 is configured to drive or actuate the upper mold 11, on which the core component 32 is placed, to move downward to close the molding apparatus 10.

[0057] 13A, 13B, and 13C show perspective, front, and side views, respectively, of molding apparatus 10 in a closed configuration, according to some embodiments of the present disclosure.

[0058] In some embodiments, when molding apparatus 10 is in a closed configuration, mold cavities 19 are formed and each core component 32 is positioned within a corresponding mold cavity 19 without contacting outer intermediate mold 15, slider 171 or 172, lower mold 13, and bottom component 34. In some embodiments, a first mold cavity 19a is defined by top mold 11, first bottom component 34a, first portion 151 of outer intermediate mold 15, and first slider 171, and a first core component 32a is positioned within first mold cavity 19a and suspended by first support unit 14a. In some embodiments, a second mold cavity 19b is defined by top mold 11, second bottom component 34b, second portion 152 of outer intermediate mold 15, and second slider 172, and a second core component 32b is positioned within second mold cavity 19b and suspended by second support unit 14b. In some embodiments, the first core component 32a completely overlaps the first bottom component 34a, and the second core component 32b completely overlaps the second bottom component 34b.

[0059] 14A and 14B show front and side perspective views, respectively, of a molding apparatus 10 in which a polymeric material M1 is injected into a mold cavity 19 to form an article 30, according to some embodiments of the present disclosure. FIG. 15 shows a perspective view of an article 30, according to some embodiments of the present disclosure.

[0060] In some embodiments, polymeric material M1 is injected into first mold cavity 19a through opening 121a of first supply port 12a to form article 30a, and polymeric material M1 is injected into second mold cavity 19b through opening 121b of second supply port 12b to form article 30b. In some embodiments, polymeric material M1 includes thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or any other suitable material. In some embodiments, the polymeric material includes a physical blowing agent such as a supercritical fluid. In some embodiments, the physical blowing agent is nitrogen gas, carbon dioxide, or the like. In some embodiments, polymeric material M1 is foamed, non-foamed, or micro-foamed. In some embodiments, polymeric material M1 includes a dye. In some embodiments, core component 32 is denser than bottom component 34 and polymeric material M1. In some embodiments, polymeric material M1 forms a layer that completely fills first mold cavity 19a and second mold cavity 19b. In some embodiments, multiple polymeric materials are injected into the first mold cavity 19a and the second mold cavity 19b. In some embodiments, different polymeric materials are injected into the first mold cavity 19a and the second mold cavity 19b simultaneously.

[0061] In some embodiments, polymeric material M1 is injected into mold cavity 19 and adheres to bottom component 34. In some embodiments, polymeric material M1 flows into bottom component 34 through opening 321 in core component 32. In some embodiments, core component 32 is completely surrounded by polymeric material M1. In some embodiments, multiple polymeric materials are injected sequentially into mold cavity 19 to form multiple layers of material within mold cavity 19, with core component 32 positioned between the different layers of material.

[0062] In some embodiments, the gap G2 (shown in FIG. 8B ) between the upper mold 11 and the core component 32 is zero, and the polymeric material M1 partially surrounds the core component 32. For example, the polymeric material M1 surrounds the bottom and sides of the core component 32 such that the top of the core component 32 is exposed to the article 30.

[0063] In some embodiments, different polymeric materials are injected into mold cavity 19 through individual feed ports 12. For example, as shown in Figure 14B, a first polymeric material is injected into mold cavity 19b through opening 121b of left feed port 12b, a second polymeric material is injected into mold cavity 19b through opening 121b of middle feed port 12b, and a third polymeric material is injected into mold cavity 19b through opening 121b of right feed port 12b.

[0064] In some embodiments, the polymeric material M1 is also injected into the mold cavity 19 through a feed port (not shown) in the outer intermediate mold 15.

[0065] In some embodiments, the support unit 14 is extendable or movable, and the support unit 14 is separated from the core component 32 by being pulled into the upper mold 11 after the polymer material M1 is injected into the mold cavity 19 or after the core component 32 is surrounded by the polymer material M1.

[0066] In some embodiments, after articles 30a, 30b are formed in molding apparatus 10, articles 30a, 30b are removed from first mold cavity 19a and second mold cavity 19b, respectively. In some embodiments, molding apparatus 10 is in an open configuration during removal of article 30. In some embodiments, article 30 includes a bottom component 34 and a top component formed by core component 32 and polymeric material M1. In some embodiments, bottom component 34 is separated from core component 32 by polymeric material M1. In some embodiments, article 30 does not include an adhesive.

[0067] In some embodiments, after the article 30 is formed, the top mold 11 is removed from the outer intermediate mold 15 and the bottom mold 13 so that the article 30 can be removed from the outer intermediate mold 15 and the bottom mold 13. In some embodiments, before moving the top mold 11 and the article 30 away from the outer intermediate mold 15, the first and second portions 151, 152 of the outer intermediate mold 15 are moved away from each other to increase the gap G1, shown in FIG. 10A , between the first and second portions 151, 152, so that the article 30 can be separated from the outer intermediate mold 15 and easily removed from the mold cavity 19.

[0068] In some embodiments, the upper mold 11 further includes an inner core. In some embodiments, a mold cavity is defined by the inner core of the upper mold 11, the lower mold 13, the outer intermediate mold 15, and the slider 171 or 172. In some embodiments, the top surface of the article 30 has a recess formed by the inner core of the upper mold 11.

[0069] 16 shows a side perspective view of a molding apparatus 10 including an inner mold 113, according to some embodiments of the present disclosure. In some embodiments, when the molding apparatus 10 is in an open configuration, the inner mold 113 is attached to the upper mold 11. In some embodiments, a mold cavity 19 is defined by the inner mold 113, the upper mold 11, the lower mold 13, the outer intermediate mold 15, and the inner intermediate mold 17. In some embodiments, the inner mold 113 comprises a shoe last. In some embodiments, a polymeric material M1 is injected into the mold cavity 19 to form a layer between the inner mold 113 and the bottom component 34. In some embodiments, a component (or core component 32) is attached to the inner mold 113, and the polymeric material M1 is injected into the mold cavity 19 to form a layer between the component attached to the inner mold 113 and the bottom component 34. This layer is formed by physical foaming of the polymeric material M1 within the mold cavity 19.

[0070] 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 should appreciate that this disclosure may readily serve as a basis for designing or modifying other processes and structures to achieve the same purposes and / or advantages of the embodiments presented herein. Those skilled in the art should also appreciate that such equivalent structures do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations can be made herein without departing from the spirit and scope of the present disclosure.

[0071] Furthermore, 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. Those skilled in the art will readily appreciate from the present disclosure that any now-existing or future-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 can be utilized in accordance with the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, and steps.

Claims

1. providing a molding apparatus including a first mold, a second mold above the first mold, and an intermediate mold between the first mold and the second mold; placing a first component in the second mold; placing the first component in the second mold and then engaging the intermediate mold with the first mold and the second mold to form a mold cavity; injecting a polymeric material into the mold cavity to surround the first component; and obtaining an article formed from said polymeric material and said first component.

2. The step of engaging the intermediate mold with the first mold and the second mold includes: moving the intermediate mold above the first mold; and placing the second mold above the intermediate mold.

3. The step of placing the first component in the second mold includes: fixing the first component to the second mold with a support unit protruding from the second mold and at least partially surrounded by the first component; and retracting the support unit into the second mold after injecting the polymeric material.

4. further comprising the step of placing a second component into the first mold before engaging the intermediate mold with the first and second molds to form a mold cavity; The injection molding method of claim 1 , wherein the second component adheres to the polymeric material when the polymeric material is injected into the mold cavity.

5. The step of placing the second component in the first mold comprises: moving the first and second portions of the intermediate mold away from each other to expose the recess in the first mold; The injection molding method of claim 4 further comprising the step of: placing the second component in the cavity of the first mold.

6. 6. The injection molding method of claim 5, wherein the intermediate mold comprises an outer intermediate mold including the first and second portions of the intermediate mold, and an inner intermediate mold including first and second sliders.

7. The step of moving the first and second portions of the outer intermediate mold away from each other includes: separating the first portion of the outer intermediate mold from the first slider; The injection molding method of claim 6, further comprising the step of: separating the second portion of the outer intermediate mold from the second slider.

8. a molding apparatus including a first mold, a second mold above the first mold, and an intermediate mold between the first mold and the second mold; the second mold includes a support unit that is extendable and retractable relative to the second mold and faces the first mold; The injection molding system, wherein the intermediate mold includes an outer intermediate mold and an inner intermediate mold surrounded by the outer intermediate mold and movable relative to the outer intermediate mold.

9. 9. The injection molding system of claim 8, wherein the outer intermediate mold includes a first portion and a second portion movable relative to the first portion, and the inner intermediate mold includes a first slider and a second slider movable relative to the first slider.

10. 10. The injection molding system of claim 9, wherein the first portion of the outer intermediate mold is movable relative to the first slider and the second portion of the outer intermediate mold is movable relative to the second slider.

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