Molding apparatus and molding method

Abstract

To provide a molding apparatus capable of uniformly and rapidly distributing a mixture in a cavity in consideration of the flowability of the mixture and capable of keeping physical characteristics, and a molding method.SOLUTION: The molding device includes a mold having a mold cavity, a feed inlet extending into the mold, a passage communicating with the feed inlet and communicable with the mold cavity, and an opening communicating with the passage and communicable with the mold cavity, wherein the feed inlet is disposed above the mold cavity, and the opening is disposed at a side of the mold cavity.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Patent Application No. 18 / 748,126, filed June 20, 2024, which is incorporated herein by reference in its entirety.

[0002] Technical Field The present invention relates to a molding apparatus and a molding method thereof, and more particularly to a molding apparatus and a molding method thereof that are suitable for use in injection molding or extrusion molding. [Background technology]

[0003] Foamed polymer molded products have many advantages, such as high strength, light weight, impact resistance, excellent sound insulation, and thermal insulation. Foamed polymer molded products can be produced as molded products having a predetermined shape by injection molding or extrusion molding. For example, a polymer material is melted and mixed with a blowing agent in an injection molding machine to form a mixture, and then the molten polymer material is injected or extruded into a mold cavity of a mold under pressure to form a desired foamed polymer molded product. The properties and applications of the foamed polymer molded product can be changed by changing the composition of the mixture and adjusting the molding method.

[0004] Generally, since the forming process directly affects the appearance and physical properties of the foamed polymer molded product, the mold design must take into account the fluidity of the mixture so that the mixture can be distributed uniformly and quickly within the cavity, and the original physical properties must be maintained by ensuring a high and uniform distribution density of the cell pores within the mixture during the forming process. Foamed polymer molded products formed using molds have many advantages and applications, but they still have drawbacks and limitations that have not yet been overcome. Summary of the Invention

[0005] SUMMARY OF THE INVENTION It is an object of the present invention to provide a molding apparatus and method.

[0006] According to one embodiment of the present disclosure, a molding apparatus is provided. The molding apparatus includes a mold and a pressure regulation system. The mold has a mold cavity, a supply port communicating with the mold cavity, and an inner wall defining the mold cavity. The pressure regulation system includes a first gas conduit, a first valve, a pressure detection unit, a second gas conduit, and a second valve. The first gas conduit is connected to the mold and communicates with the mold cavity. The first valve is disposed in the first gas conduit and configured to control injection of gas from a gas source through the first gas conduit into the mold cavity. The pressure detection unit is configured to detect pressure within the mold cavity. The second gas conduit is connected to the mold and communicates with the mold cavity. The second valve is disposed in the second gas conduit and configured to control discharge of gas from the mold cavity.

[0007] According to one embodiment of the present disclosure, a molding method is disclosed. The molding method includes the steps of providing a mold, the mold including a mold cavity, a supply port communicating with the mold cavity, a connection point connected to the mold cavity, and an inner wall defining the mold cavity, detecting a pressure within the mold cavity and injecting a gas into the mold cavity through the connection point until it is detected that the mold cavity has a first predetermined pressure. The molding method further includes the steps of detecting the pressure within the mold cavity, filling the mold cavity having the first predetermined pressure with material through the supply port, and discharging a portion of the gas within the mold cavity through the connection point. [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: It should be noted that, in accordance with standard industry practice, various features have not been drawn to scale. In fact, the dimensions of various features may be arbitrarily increased or decreased for clarity of illustration.

[0009] [Figure 1] 1 is a schematic diagram of a molding device according to an embodiment of the present invention. [Figure 2] 1 is a schematic diagram of a molding device according to an embodiment of the present invention. [Figure 3] 1 is a schematic diagram of a molding device according to an embodiment of the present invention. [Figure 4] 1 is a schematic diagram of a molding device according to an embodiment of the present invention. [Figure 5] 1 is a top view showing a part of a molding apparatus according to an embodiment of the present invention. [Figure 6] 1 is a flowchart illustrating a molding method according to an embodiment of the present invention. [Figure 7] FIG. 1 is a schematic side view of a molding apparatus in a closed configuration, according to one embodiment of the present invention. [Figure 8] 8 is a schematic cross-sectional view of the molding apparatus of FIG. 7 in a closed configuration. [Figure 9] 8 is a schematic cross-sectional view of the molding apparatus of FIG. 7 in an open configuration. [Figure 10] FIG. 8 is a schematic top view of the molding device of FIG. 7. [Figure 11] 9 is a schematic cross-sectional view of the molding device of FIG. 8 taken along line AA'. [Figure 12] 8 is a schematic cross-sectional view of the molding apparatus of FIG. 7 in an open configuration. [Figure 13] FIG. 1 is a schematic side view of a molding apparatus in a closed configuration, according to one embodiment of the present invention. [Figure 14] 14 is a schematic cross-sectional view of the molding apparatus of FIG. 13 in a closed configuration. [Figure 15] FIG. 14 is a schematic cross-sectional view of the molding apparatus of FIG. 13 in an open configuration. [Figure 16] FIG. 14 is a schematic top view of the molding apparatus of FIG. 13. [Figure 17] 15 is a schematic cross-sectional view of the molding device of FIG. 14 taken along line AA'. [Figure 18] FIG. 14 is a schematic cross-sectional view of the molding apparatus of FIG. 13 in an open configuration. [Figure 19] FIG. 1 is a schematic side view of a molding apparatus in a closed configuration, according to one embodiment of the present invention. [Figure 20] FIG. 20 is a schematic cross-sectional view of the molding apparatus of FIG. 19 in an open configuration. [Figure 21] FIG. 20 is a schematic top view of the molding apparatus of FIG. 19. [Figure 22] 21 is a schematic cross-sectional view of the molding device of FIG. 20 taken along line AA'. [Figure 23] FIG. 14 is a schematic cross-sectional view of the molding apparatus of FIG. 13 in an open configuration. [Figure 24] FIG. 1 is a schematic side view of a molding apparatus in a closed configuration, according to one embodiment of the present invention. [Figure 25] FIG. 25 is a schematic cross-sectional view of the molding apparatus of FIG. 24 in a closed configuration. [Figure 26] FIG. 25 is a schematic cross-sectional view of the molding apparatus of FIG. 24 in an open configuration. [Figure 27] FIG. 25 is a schematic top view of the molding apparatus of FIG. 24. [Figure 28] 26 is a schematic cross-sectional view of the molding device of FIG. 25 taken along line AA'. [Figure 29] FIG. 25 is a schematic cross-sectional view of the molding apparatus of FIG. 24 in an open configuration. [Figure 30] FIG. 1 is a schematic side view of a molding apparatus in a closed configuration, according to one embodiment of the present invention. [Figure 31] FIG. 31 is a schematic cross-sectional view of the molding apparatus of FIG. 30 in a closed configuration. [Figure 32] FIG. 31 is a schematic cross-sectional view of the molding apparatus of FIG. 30 in an open configuration. [Figure 33] FIG. 31 is a schematic top view of the molding apparatus of FIG. 30. [Figure 34] 32 is a schematic cross-sectional view of the molding device of FIG. 31 taken along line AA'. [Figure 35] FIG. 31 is a schematic cross-sectional view of the molding apparatus of FIG. 30 in an open configuration. [Figure 36] 1 is a flowchart illustrating a molding method according to an embodiment of the present invention. [Figure 37] 37A-37C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 36 according to an embodiment of the present disclosure. [Figure 38] 37A-37C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 36 according to an embodiment of the present disclosure. [Figure 39]37A-37C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 36 according to an embodiment of the present disclosure. [Figure 40] 37A-37C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 36 according to an embodiment of the present disclosure. [Figure 41] 37A-37C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 36 according to an embodiment of the present disclosure. [Figure 42] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 43] 37A-37C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 36 according to an embodiment of the present disclosure. [Figure 44] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 45] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 46] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 47] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 48] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 49] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 50] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 51] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 52] 37A-37C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 36 according to an embodiment of the present disclosure. [Figure 53] 37A-37C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 36 according to an embodiment of the present disclosure. [Figure 54] 37A-37C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 36 according to an embodiment of the present disclosure. [Figure 55]37A-37C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 36 according to an embodiment of the present disclosure. [Figure 56] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 57] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 58] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 59] 31A-31C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 30 according to an embodiment of the present disclosure. [Figure 60] 31A-31C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 30 according to an embodiment of the present disclosure. [Figure 61] 31A-31C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 30 according to an embodiment of the present disclosure. [Figure 62] 31A-31C are schematic cross-sectional views illustrating exemplary stages in the molding method of FIG. 30 according to an embodiment of the present disclosure. [Figure 63] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 64] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. [Figure 65] FIG. 37 is a schematic perspective view of a foam member manufactured by the molding method of FIG. 36. 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, the formation of a first feature over or on a second feature may include an embodiment in which the first and second features are formed in direct contact with each other, and may also include 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 illustrated 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 / working examples, or unless otherwise specified, all numerical ranges, amounts, values, and percentages, such as amounts of materials, times, temperatures, operating conditions, and proportions of amounts, disclosed herein, should be understood in all instances to be modified 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, if necessary. Finally, each numerical parameter should be construed in light of at least 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] FIG. 1 is a schematic diagram of a first molding apparatus 100 according to one embodiment of the present invention. The molding apparatus 100 includes a mold 10 and a pressure regulation system 20. The mold 10 includes a mold cavity 13, a feed port 14 communicating with the mold cavity 13, and an inner wall 16 defining the mold cavity 13. In some embodiments, the mold 10 includes a connection point 15 connected to the mold cavity 13. In some embodiments, the inner wall 16 of the mold cavity 13 includes the connection point 15. The mold cavity 13 is configured to receive a material, allowing the material to be molded into a molded article having a predetermined shape through molding. In some embodiments, the feed port 14 is connected to an injection molding machine or an extruder, so that the material can be injected / extruded from the injection molding machine or extruder into the mold cavity 13 and molded into a predetermined shape therein. In some embodiments, the connection point 15 is configured to allow a fluid or gas to enter or exit the mold cavity 13.

[0014] The pressure regulation system 20 includes a first gas conduit 21, a second gas conduit 22, a gas source 23, a first valve 24, a second valve 25, and a pressure detection unit 26. The first gas conduit 21 is connected at one end to the connection point 15 and at the other end to the gas source 23. In some embodiments, the gas source 23 is configured to supply a fluid or gas, and a suitable fluid or gas may be supplied as needed, for example, the fluid or gas may be air, an inert gas, etc., but the present invention is not limited thereto.

[0015] In some embodiments, mold 10 includes a first mold substrate 11 and a second mold substrate 12, where second mold substrate 12 and first mold substrate 11 match to each other to define a mold cavity 13 between first mold substrate 11 and second mold substrate 12. In some embodiments, feed ports 14 are located in first mold substrate 11. In some embodiments, connection points 15 are located in second mold substrate 12.

[0016] The position, shape, and number of connection points 15 are not particularly limited and may be adjusted as needed. In some embodiments, connection points 15 are holes. In some embodiments, connection points 15 are disposed on the inner wall 16 or the inner bottom wall 17 of second mold substrate 12 and penetrate second mold substrate 12. In some embodiments, connection points 15 are configured to inhale and discharge gas, such that when first valve 24 is open and second valve 25 is closed, connection points 15 are configured to inhale gas, and when first valve 24 is closed and second valve 25 is open, connection points 15 are configured to discharge gas. In some embodiments, connection points 15 are not configured to simultaneously inhale and discharge gas. In some embodiments, connection point 15 is configured to supply and discharge gas, supplying fluid or gas to mold cavity 13 when first valve 24 is open and second valve 25 is closed, and discharging at least a portion of the fluid or gas in mold cavity 13 when first valve 24 is closed and second valve 25 is open.

[0017] The position, shape, and number of the supply ports 14 are not particularly limited and may be adjusted as needed. In some embodiments, the supply ports 14 are located on the inner top wall 111 or inner wall 16 of the first mold substrate 11 and penetrate the first mold substrate 11. In some embodiments, the supply ports 14 and the connection points 15 are located on opposite sides of the mold cavity 13. For example, the supply ports 14 are located on the inner top wall 111 of the first mold substrate 11 and the connection points 15 are located on the inner bottom wall 17 of the second mold substrate 12, but this is not limiting. In some embodiments, the supply ports 14 are located on the inner top wall 111 of the first mold substrate 11 and the connection points 15 are located on the inner wall 16 of the second mold substrate 12. In some embodiments, the supply ports 14 are located on the inner wall of the first mold substrate 11 and the connection points 15 are located on the inner wall 16 of the second mold substrate 12, opposite the supply ports 14. In some embodiments, the supply ports 14 are spaced apart from the connection points 15.

[0018] A first valve 24 is disposed in the first gas conduit 21 and configured to control whether gas from the gas source 23 enters the mold cavity 13 through the first gas conduit 21 and connection point 15. A second gas conduit 22 communicates with connection point 15. A second valve 25 is disposed in the second gas conduit 22 and configured to control whether gas from the mold cavity 13 is discharged through the second gas conduit 22 via connection point 15.

[0019] In some embodiments, one end of the second gas conduit 22 is connected to the first gas conduit 21 via the first gas conduit 21, which is connected to the connection point 15. In some embodiments, the other end of the second gas conduit 22 is connected to a space having a lower pressure than the pressure in the mold cavity, such as the external environment or a negative pressure space, but the present invention is not limited thereto. The connection position between the second gas conduit 22 and the first gas conduit 21 is not particularly limited. For example, the second gas conduit 22 and the first gas conduit 21 may be connected at one end adjacent to the end where the first gas conduit 21 is connected to the connection point 15. In some embodiments, the first valve 24 is disposed between the gas source 23 and the second gas conduit 22. In this manner, when gas is to be discharged from the mold cavity 13, the first valve 24 is closed and the second valve 25 is opened, allowing the gas to enter the second gas conduit 22 from the connection point 15. When gas is to enter mold cavity 13, second valve 25 is closed and first valve 24 is open, allowing gas to enter first gas conduit 21 from gas source 23 and then through connection point 15 into mold cavity 13. In some embodiments, first valve 24 and second valve 25 are not open at the same time.

[0020] Pressure detection unit 26 is configured to detect the pressure within mold cavity 13. In some embodiments, the properties of the foamed polymer are affected by the size and distribution of pores throughout the polymer, which in turn are related to temperature, pressure, and feed rate. Pressure detection unit 26 is not limited to any particular type, as long as it can detect pressure and provide pressure information after detecting the pressure within mold cavity 13. Pressure adjustment system 20 adjusts the pressure within mold cavity 13 in response to the pressure information by changing the gas inlet and outlet conditions to and from mold cavity 13, thereby causing the resulting molded product to have a desired, predetermined shape and properties.

[0021] In some embodiments, the pressure detection unit 26 is disposed within the mold cavity 13. In some embodiments, the pressure detection unit 26 is disposed on the inner wall 16, the first gas conduit 21, or the second gas conduit 22. In some embodiments, the pressure detection unit 26 is disposed on the inner wall 16 of the mold cavity 13 and away from the supply port 14. In some embodiments, the pressure regulation system 20 has a plurality of pressure detection units 26, and the number and positions of the plurality of pressure detection units 26 are not particularly limited. For example, the plurality of pressure detection units 26 may be disposed on the inner wall 16 of the mold cavity 13 and spaced apart from each other, and / or at any position within the first gas conduit 21 and / or at any position within the second gas conduit 22, but the present invention is not limited thereto.

[0022] In some embodiments, molding apparatus 100 further includes control system 30. Control system 30 is configured to control pressure regulation system 20 and mold cavity 13. In some embodiments, pressure detection unit 26 provides pressure information to control system 30, which adjusts first valve 24 and second valve 25 in response to the pressure information. In some embodiments, control system 30 adjusts gas entry and exit conditions to mold cavity 13 in real time in response to the pressure information, thereby ensuring that the pressure within mold cavity 13 is within an appropriate or predetermined pressure range at any time during the mold formation process. In some embodiments, control system 30 further controls the supply conditions of supply inlet 14 and the gas supply conditions of gas source 23. In some embodiments, control system 30, first valve 24, second valve 25, pressure detection unit 26, and supply inlet 14 are electrically connected.

[0023] 2 to 4 are schematic diagrams of a molding apparatus according to an embodiment of the present invention, and FIG. 5 is a top view showing a portion of a molding apparatus according to an embodiment of the present invention. These figures will be used to explain different configurations of the connection point 15, the first gas conduit 21, and the second gas conduit 22, as well as configurations of the connection point 15 corresponding to various configurations of the first gas conduit 21 and the second gas conduit 22. In some embodiments, the second molding apparatus 200 shown in FIG. 2 is similar to the first molding apparatus 100 shown in FIG. 1. In some embodiments, as shown in FIG. 2, the second gas conduit 22 of the second molding apparatus 200 is connected to an intermediate portion of the first gas conduit 21. In some embodiments, the second gas conduit 22 is connected to the first gas conduit 21 at a position close to the end of the first gas conduit 21 that is connected to the gas source.

[0024] In some embodiments, the third molding apparatus 300 shown in FIG. 3 is similar to the first molding apparatus 100 shown in FIG. 1. In some embodiments, as shown in FIG. 3, the connection point 15 of the third molding apparatus 300 is a hole including a first opening 151 and a second opening 152, where the first opening 151 is connected to the first gas conduit 21 and the second opening 152 is connected to the second gas conduit 22. In some embodiments, the first opening 151 is configured to intake gas, and the second opening 152 is configured to discharge gas. The locations of the first opening 151 and the second opening 152 are not particularly limited as long as they are separated from each other. In some embodiments, the first opening 151 is spaced apart from the second opening 152. In some embodiments, the first opening 151 and the second opening 152 are located on opposite sides of the supply port 14. In some embodiments, the first opening 151 and the second opening 152 are located on the bottom surface 17 of the mold cavity 13. In some embodiments, the first opening 151 and the second opening 152 are located on the inner wall 16 of the mold cavity 13 .

[0025] In some embodiments, the fourth molding apparatus 400 shown in FIG. 4 is similar to the third molding apparatus 300 shown in FIG. 3. In some embodiments, as shown in FIG. 4, the first opening 151 of the fourth molding apparatus 400 has a plurality of first pores 153, and the second opening 152 has a plurality of second pores 154. In some embodiments, the plurality of first pores 153 are connected to the first gas conduit 21, and the plurality of second pores 154 are connected to the second gas conduit 22. In some embodiments, the number of second pores 154 is greater than the number of first pores 153. The positions of the plurality of first pores 153 and the plurality of second pores 154 are not particularly limited and may be alternately arranged or may be arranged in different regions within the mold cavity 13. In some embodiments, the end of the first gas conduit 21 where it connects to the mold cavity 13 has a plurality of first guide channels 211, each connected to a corresponding first capillary 153 and the first gas conduit 21. In some embodiments, the end of the second gas conduit 22 where it connects to the mold cavity 13 has a plurality of second guide channels 221, each connected to a corresponding second capillary 154 and the second gas conduit 22.

[0026] 5, the first opening 151 of the fourth molding apparatus 400 is positioned in the center of the mold cavity, and the second opening 152 is positioned around the periphery of the mold cavity. In some embodiments, the plurality of second pores 154 surround the first opening 151. In some embodiments, the first opening 151 and the plurality of second pores 154 are positioned on the bottom surface 17 of the mold cavity 13. In some embodiments, the diameter of each second pore 154 is smaller than the diameter of the first opening 151.

[0027] 6 is a flowchart illustrating a molding method according to one embodiment of the present invention. In some embodiments, as shown in FIG. 6, molding method 600 includes the following steps:

[0028] In step 61, a mold is provided, the mold including a mold cavity, a feed port communicating with the mold cavity, a connection point connected to the mold cavity, and an inner wall defining the mold cavity.

[0029] In step 62, the pressure within the mold cavity is sensed and gas is injected into the mold cavity through the connection point until the mold cavity is sensed to have a first predetermined pressure.

[0030] In step 63, the pressure in the mold cavity is detected and material is filled into the mold cavity from the supply port at a first predetermined pressure.

[0031] In step 64, a portion of the gas within the mold cavity is vented through the connection point.

[0032] The molding method is not limited to the above embodiments. In some embodiments, molding method 600 uses any of molding apparatuses 100, 200, 300, and 400 as shown in FIGS.

[0033] In some embodiments, molding method 600 includes the following steps 61 to 64. In step 61, a mold 10 is provided. The mold 10 includes a mold cavity 13, a supply port 14 communicating with the mold cavity, and a connection point 15 communicating with the mold cavity. In some embodiments, the mold 10 is the mold 10 of any of molding apparatuses 100, 200, 300, and 400 shown in FIGS. 1 to 5.

[0034] In some embodiments, at the start of step 62, pressure detection unit 26 detects that the pressure within mold cavity 13 is atmospheric pressure. In some embodiments, in step 62, first valve 24 opens to inject gas from gas source 23 through first gas conduit 21 and connection point 15 into mold cavity 13. In some embodiments, the pressure within mold cavity 13 is continuously detected during the process of injecting gas into mold cavity 13. In some embodiments, when first valve 24 opens and second valve 25 closes, gas is injected into mold cavity 13 through first gas conduit 21. In some embodiments, pressure detection unit 26 continuously detects the pressure within the mold cavity and injects gas into mold cavity 13 until it detects that mold cavity 13 has a first predetermined pressure, after which first valve 24 is closed, stopping the injection of gas into mold cavity 13. In some embodiments, the first predetermined pressure is greater than atmospheric pressure. In some embodiments, the first predetermined pressure is less than atmospheric pressure.

[0035] In some embodiments, the gas is any suitable gas as desired, such as air, although the invention is not limited thereto.

[0036] In some embodiments, in step 63, pressure sensing unit 26 continuously senses the pressure within mold cavity 13 during the process of filling mold cavity 13 with material. In some embodiments, material can be injected into mold cavity 13 from inlet 14, thereby increasing the pressure within mold cavity 13. In some embodiments, the pressure within mold cavity 13 is increased from a first predetermined pressure. In some embodiments, the pressure within mold cavity 13 is increased from the first predetermined pressure to a second predetermined pressure.

[0037] In some embodiments, the material comprises a mixture. In some embodiments, the mixture comprises a high-molecular-weight polymer and a blowing agent. In some embodiments, the blowing agent is a physical or chemical additive that forms pores by releasing gas during a heating process. Because the gasification process of the physical or chemical additive is very rigorous and the temperature distribution throughout the foamed polymer molded article is non-uniform, the resulting foamed polymer molded article has a flat shape and larger pores. However, in this molding method, the pressure within the mold cavity 13 may be detected and adjusted at any time, and the resulting foamed polymer molded article may have a substantially increased thickness and more uniformly and densely distributed pores. In some embodiments, the blowing agent is a physical additive. In some embodiments, the blowing agent is a supercritical fluid (SCF).

[0038] In some embodiments, the first predetermined pressure and the second predetermined pressure may be adjusted depending on the characteristics of the material. The lower the strength of the material, the higher the first predetermined pressure, and the higher the strength of the material, the lower the first predetermined pressure. In some embodiments, after the material is filled into mold cavity 13 at the first predetermined pressure, the pressure in mold cavity 13 increases, so setting the second predetermined pressure ensures that the mold cavity is maintained within an appropriate pressure range. In some embodiments, when mold cavity 13 has the second predetermined pressure, filling of mold cavity 13 with material is stopped.

[0039] In some embodiments, step 64 includes injecting gas into mold cavity 13 and discharging some of the gas from the mold cavity after completing filling of the material into mold cavity 13. In some embodiments, step 64 discharges gas from mold cavity 13 by opening second valve 25 and closing first valve 24, allowing gas to enter second gas conduit 22.

[0040] In some embodiments, if the pressure in mold cavity 13 is detected to be greater than a second predetermined pressure, some of the gas in mold cavity 13 is vented through connection point 15 until the pressure in mold cavity 13 is maintained within a predetermined pressure range. In some embodiments, the predetermined pressure range is between the first predetermined pressure and the second predetermined pressure.

[0041] In some embodiments, the process from when material is filled into mold cavity 13 at first predetermined pressure through supply port 14 to when filling of the material is completed lasts only 0.5 to 1 second, so the pressure in mold cavity 13 changes rapidly during the filling period. During the filling period or when filling is completed, pressure detection unit 26 detects the pressure in mold cavity 13 in real time and provides pressure information, so that pressure regulation system 20 can adjust the flow of gas into and out of mold cavity 13 according to the pressure information, thereby maintaining the pressure in mold cavity 13 within a predetermined pressure range of the first predetermined pressure.

[0042] In some embodiments, the method further includes using a control system 30 to control the injection of gas into the mold cavity 13 and to control the discharge of gas within the mold cavity 13 in response to the pressure within the mold cavity 13 detected by the pressure detection unit 26. In some embodiments, the control system 30 receives pressure information provided by the pressure detection unit 26, and in response to the pressure information, controls the on / off status of the first valve 24 and the second valve 25, and controls the material supply conditions of the supply port 14 (including, but not limited to, the supply time, supply rate, etc. of the supply port 14).

[0043] In view of the above, the molding apparatus and molding method of the present invention use a molding apparatus including a mold and a pressure adjustment system connected to the mold, which includes a pressure detection unit configured to detect the pressure within the mold cavity, thereby providing a first predetermined pressure to the mold cavity before supply, and when performing the molding method of the present invention, making it possible to adjust the pressure within the mold cavity in real time depending on the supply conditions and the detection results of the pressure detection unit, so that the molded product thus produced has good appearance and quality.

[0044] FIG. 7 is a schematic side view of a molding apparatus 500 according to one embodiment of the present invention, FIG. 8 is a schematic cross-sectional view of the molding apparatus 500 in a closed configuration, and FIG. 9 is a schematic cross-sectional view of the molding apparatus in an open configuration. The molding apparatus 500 includes a mold having a first mold 501 and a second mold 502 disposed above the first mold 501. The first mold 501 is engageable with the second mold 502. The first mold 501 engages with the second mold 502 when the molding apparatus 500 is in the closed configuration, as shown in FIGS. 7 and 8. In some embodiments, the first mold 501 is a lower mold, and the second mold 502 is an upper mold.

[0045] The mold cavity 503 is defined by the first mold 501 and the second mold 502. The mold cavity 503 is formed when the molding apparatus 500 is in a closed configuration. The mold cavity 503 is configured to receive and hold a flowable mixture. In some embodiments, a mixture including a polymeric material (such as polyurethane (PU), thermoplastic polyurethane (TPU)) and a blowing agent (a physical blowing agent, e.g., carbon dioxide, nitrogen, a supercritical fluid, etc.) may be injected into the mold cavity 503. The mixture may undergo a foaming process within the mold cavity 503. The mixture within the mold cavity 503 becomes a foamed molded product after the foaming process.

[0046] The molding apparatus 500 includes a feed port 504 disposed in the first mold 501 or the second mold 502. The feed port 504 is configured to receive a discharge channel or injector of an injection unit. In some embodiments, the discharge channel of the injection unit is engageable with the feed port 504. In some embodiments, when the discharge channel of the injection unit engages with the feed port 504, a mixture including a polymeric material and a blowing agent may be injected into the mold cavity 503. The mixture can flow from the injection unit to the mold cavity 503 through the feed port 504. In some embodiments, the feed port 504 is disposed in the top surface of the first mold 501 or the top surface 502a of the second mold 502. In some embodiments, the feed port 504 extends vertically into the first mold 501 or the second mold 502.

[0047] The molding apparatus 500 has a passage 505 disposed in the first mold 501 or the second mold 502. The passage 505 is configured to allow a mixture including a polymeric material and a blowing agent to flow. The passage 505 connects a supply inlet 504 and a mold cavity 503. The passage 505 can be in communication with the supply inlet 504 and the mold cavity 503. In some embodiments, the passage 505 includes multiple portions 505a, 505b extending into the first mold 501 or the second mold 502.

[0048] FIG. 10 shows a top view of FIG. 7 , and FIG. 11 shows a cross-sectional view along line AA′ of FIG. 8 . In some embodiments, the passage 505 includes a first portion 505a and a second portion 505b that connects to the first portion 505a. The mixture can flow from the injection unit through the injection unit's discharge channel, the supply port 504, the first portion 505a, and the second portion 505b into the mold cavity 503. In some embodiments, one end of the first portion 505a connects to the supply port 504, and the other end of the first portion 505a connects to the second portion 505b. In some embodiments, the mixture can flow diagonally along the first portion 505a. In some embodiments, the first portion 505a is not parallel to the supply port 504, and there is an angle α between the first portion 505a and the supply port 504. In some embodiments, the angle α is greater than 90° but less than 180°. In some embodiments, one end of the second portion 505b connects to the first portion 505a and the other end of the second portion 505b connects to the mold cavity 503.

[0049] In some embodiments, the second portion 505b extends substantially perpendicular to the feed opening 504. In some embodiments, the second portion 505b extends substantially parallel to the top surface 502a. In some embodiments, there is an angle β between the first portion 505a and the second portion 505b. In some embodiments, the angle β is less than 90°. In some embodiments, the angle α is substantially greater than the angle β. In some embodiments, the second portion 505b has a tapered configuration that narrows from the mold cavity 503 toward the periphery of the first mold 501 or the second mold 502. In some embodiments, the second portion 505b has a flat tapered configuration. In some embodiments, the width of the opening 503a along the first mold 501 or the second mold 502, which is disposed between the mold cavity 503 and the second portion 505b, is substantially greater than the width or diameter of the first portion 505a. In some embodiments, the width of the opening 503a is substantially greater than the width or diameter of the feed opening 504. In some embodiments, the opening 503a is located on a side of the mold cavity 503. In some embodiments, the opening 503a is located on an inner wall 502f of the second mold 502. In some embodiments, the inner wall 502f is substantially perpendicular to the top surface 502a of the second mold 502.

[0050] FIG. 12 is an exploded cross-sectional view of FIG. 9. In some embodiments, first mold 501 includes multiple separable parts, and second mold 502 also includes multiple separable parts. For simplicity and clarity, only second mold 502 having separable parts is shown and described, but it is understood that first mold 501 can have a similar configuration to second mold 502. In some embodiments, second mold 502 can be separated into multiple parts when molding apparatus 500 is in an open configuration as shown in FIG. 9 or FIG. 12. In some embodiments, second mold 502 includes first part 502b, second part 502c, and third part 502d. First part 502b, second part 502c, and third part 502d are separable from one another. In some embodiments, passageway 505 is formed when first part 502b engages with second part 502c, as shown in FIG. 9, or when molding apparatus 500 is in a closed configuration as shown in FIG. 8. In some embodiments, first portion 505a and second portion 505b of passageway 505 are formed when first part 502b engages second part 502c. In some embodiments, first part 502b and second part 502c are mold parts of molding apparatus 500.

[0051] In some embodiments, the second mold 502 includes a third part 502d. In some embodiments, the feed port 504 is disposed in the third part 502d. In some embodiments, the feed port 504 extends through the third part 502d. In some embodiments, the feed port 504 communicates with the passageway 505 when the first part 502b, the second part 502c, and the third part 502d are engaged with one another, as shown in FIG. 9, or when the molding apparatus 500 is in a closed configuration, as shown in FIG. 8. In some embodiments, the third part 502d is disposed above the first part 502b and the second part 502c. In some embodiments, the feed port 504 communicates with the passageway 505 after the first part 502b, the second part 502c, and the third part 502d are engaged, as shown in FIG. 9. In some embodiments, when first part 502b, second part 502c, and third part 502d are engaged with one another, as shown in Figure 9, or when molding apparatus 500 is in a closed configuration, as shown in Figure 8, feed inlet 504 can communicate with mold cavity 503 through passage 505. Thus, the mixture can flow from feed inlet 504 through passage 505 into mold cavity 503. In some embodiments, feed inlet 504 can be engaged with a discharge channel of an injection unit, so that the mixture can be injected from the injection unit into mold cavity 503 by flowing through passage 505.

[0052] FIG. 13 is a schematic side view of a molding apparatus 800 according to one embodiment of the present invention, FIG. 14 is a schematic cross-sectional view of molding apparatus 800 in a closed configuration, and FIG. 15 is a schematic cross-sectional view of molding apparatus 800 in an open configuration. FIG. 16 shows a top view of FIG. 13, and FIG. 17 shows a cross-sectional view along line AA' of FIG. 14. Molding apparatus 800 is similar to molding apparatus 500 described above and shown in FIGS. 7-11. In some embodiments, molding apparatus 800 includes multiple passageways 505. In some embodiments, molding apparatus 800 includes a first passageway 505-1 and a second passageway 505-2 similar to first passageway 505-1. In some embodiments, first passageway 505-1 is configured symmetrically with second passageway 505-2.

[0053] In some embodiments, the first passage 505-1 includes a first portion 505a and a second portion 505b, and the second passage 505-2 includes a third portion 505c and a fourth portion 505d. In some embodiments, the first portion 505a is similar to the third portion 505c, and the second portion 505b is similar to the fourth portion 505d. In some embodiments, the supply port 504 communicates with the first passage 505-1 and the second passage 505-2. In some embodiments, the mold cavity 503 communicates with the first passage 505-1 and the second passage 505-2 through a first opening 503a-1 and a second opening 503a-2, respectively. In some embodiments, the first opening 503a-1 and the second opening 503a-2 are disposed in the inner wall 502f of the second mold 502. In some embodiments, the inner wall 502f is substantially perpendicular to the top surface 502a of the second mold 502. In some embodiments, the first angle α1 between the feed inlet 504 and the first portion 505a is substantially the same as the second angle α2 between the feed inlet 504 and the third portion 505c. In some embodiments, the third angle β1 between the first portion 505a and the second portion 505b is substantially the same as the fourth angle β2 between the third portion 505c and the fourth portion 505d. In some embodiments, the mixture can flow from the feed inlet 504 into the mold cavity 503 through the first portion 505a and the second portion 505b and / or through the third portion 505c and the fourth portion 505d.

[0054] FIG. 18 shows an exploded cross-sectional view of FIG. 15. In some embodiments, second mold 502 may be separated into multiple parts when molding apparatus 800 is in an open configuration as shown in FIG. 15 or 18. In some embodiments, second mold 502 includes first part 502b, second part 502c, third part 502d, and fourth part 502e. First part 502b, second part 502c, third part 502d, and fourth part 502e are separable from one another. In some embodiments, first passageway 505-1 and second passageway 505-2 are formed when first part 502b, second part 502c, and fourth part 502e engage with one another as shown in FIG. 15, or when molding apparatus 800 is in a closed configuration as shown in FIG. 14. In some embodiments, when the first part 502b, the second part 502c, and the fourth part 502e engage with each other, a first portion 505a and a second portion 505b of the first passage 505-1 and a third portion 505c and a fourth portion 505d of the second passage 505-2 are formed. In some embodiments, the first part 502b, the second part 502c, the third part 502d, and the fourth part 502e are mold parts of the molding apparatus 800.

[0055] FIG. 19 is a schematic side view of a molding apparatus 700 according to one embodiment of the present invention, and FIG. 20 is a schematic cross-sectional view of molding apparatus 700 in an open configuration. FIG. 21 shows a top view of FIG. 19, and FIG. 22 shows a cross-sectional view along line AA′ of FIG. 20. Molding apparatus 700 is similar to molding apparatus 500 or molding apparatus 800 described above and shown in FIGS. 7-18. In some embodiments, molding apparatus 700 includes multiple passages 505. In some embodiments, molding apparatus 700 includes a first passage 505-1, a second passage 505-2, a third passage 505-3, and a fourth passage 505-4. In some embodiments, first passage 505-1 is configured symmetrically with second passage 505-2, and third passage 505-3 is configured symmetrically with fourth passage 505-4.

[0056] In some embodiments, the first passage 505-1 includes a first portion 505a and a second portion 505b, the second passage 505-2 includes a third portion 505c and a fourth portion 505d, the third passage 505-3 includes a fifth portion 505e and a sixth portion 505f, and the fourth passage 505-4 includes a seventh portion 505g and an eighth portion 505h. In some embodiments, the first portion 505a, the third portion 505c, and the fifth portion 505e are similar to one another, and the second portion 505b, the fourth portion 505d, and the sixth portion 505f are similar to one another. In some embodiments, the supply port 504 communicates with the first passage 505-1, the second passage 505-2, the third passage 505-3, and the fourth passage 505-4. In some embodiments, the mold cavity 503 communicates with the first passage 505-1, the second passage 505-2, the third passage 505-3, and the fourth passage 505-4 through the first opening 503a-1, the second opening 503a-2, the third opening 503a-3, and the fourth opening 503a-4, respectively. In some embodiments, the first opening 503a-1, the second opening 503a-2, the third opening 503a-3, and the fourth opening 503a-4 are disposed on an inner wall 502f of the second mold 502. In some embodiments, the inner wall 502f is substantially perpendicular to the top surface 502a of the second mold 502.

[0057] Figure 23 is an exploded cross-sectional view of Figure 20. In some embodiments, the second mold 502 may be separated into multiple parts when the molding apparatus 700 is in an open configuration as shown in Figure 20. In some embodiments, the second mold 502 includes a first part 502b, a second part 502c, a third part 502d, a fourth part 502e, and a fifth part 502f. The first part 502b, the second part 502c, the third part 502d, the fourth part 502e, and the fifth part 502f are separable from one another. In some embodiments, when the first part 502b, the second part 502c, the third part 502d, the fourth part 502e, and the fifth part 502f engage with one another as shown in Figure 20, or when the molding apparatus 800 is in a closed configuration as shown in Figure 19, a first passageway 505-1, a second passageway 505-2, a third passageway 505-3, and a fourth passageway 505-4 are formed. In some embodiments, the first part 502b, the second part 502c, the third part 502d, the fourth part 502e, and the fifth part 502f are mold parts of the molding apparatus 700.

[0058] Figure 24 is a schematic side view of molding apparatus 1000 according to one embodiment of the present invention, Figure 25 is a schematic cross-sectional view of molding apparatus 1000 in a closed configuration, and Figure 26 is a schematic cross-sectional view of molding apparatus 1000 in an open configuration. Figure 27 shows a top view of Figure 24, and Figure 28 shows a cross-sectional view along line A-A' of Figure 25. Molding apparatus 1000 is similar to molding apparatus 500, molding apparatus 700, or molding apparatus 800 described above and shown in Figures 7-23.

[0059] In some embodiments, the passageway 505 includes a first portion 505a and a second portion 505b. In some embodiments, the first portion 505a is in the second mold 502 and the second portion 505b is in the first mold 501. The second portion 505b is a recess 501a in the first mold 501 and is recessed toward the first mold 501. In some embodiments, the mixture can flow from the feed port 504 through the first portion 505a and the second portion 505b into the mold cavity 503.

[0060] Figure 29 shows an exploded cross-sectional view of Figure 25. In some embodiments, second mold 502 may be separated into multiple parts when molding apparatus 1000 is in the open configuration as shown in Figure 29. In some embodiments, second mold 502 includes first part 502b and second part 502c that are separable from one another. In some embodiments, passageway 505 is formed when first part 502b and second part 502c engage with one another and when molding apparatus 1000 is in the closed configuration as shown in Figure 25.

[0061] FIG. 30 is a schematic side view of a molding apparatus 1001 according to one embodiment of the present invention, FIG. 31 is a schematic cross-sectional view of the molding apparatus 1001 in a closed configuration, and FIG. 32 is a schematic cross-sectional view of the molding apparatus 1001 in an open configuration. FIG. 33 shows a top view of FIG. 30, and FIG. 34 shows a cross-sectional view along line A-A' of FIG. 30. The molding apparatus 1001 is similar to the molding apparatus 500, 700, 800, or 1000 described above and shown in FIGS. 7-29. In some embodiments, the molding apparatus 1001 includes multiple feed ports 504 and multiple passages 505. In some embodiments, the molding apparatus 1001 includes a first passage 505-1 and a second passage 505-2 similar to the first passage 505-1. In some embodiments, the first passage 505-1 is configured symmetrically with the second passage 505-2.

[0062] In some embodiments, the first passage 505-1 includes a first portion 505a and a second portion 505b, and the second passage 505-2 includes a third portion 505c and a fourth portion 505d. In some embodiments, the first portion 505a is similar to the third portion 505c, and the second portion 505b is similar to the fourth portion 505d. In some embodiments, the first portion 505a and the third portion 505c are in the second mold 502, and the second portion 505c and the fourth portion 505d are in the first mold 501 and are recessed toward the first mold 501. The second portion 505c and the fourth portion 505d are recesses 501a of the first mold 501. The first portion 505a and the third portion 505c extend into the first mold 501.

[0063] In some embodiments, the third angle β1 between the first portion 505a and the second portion 505b is substantially the same as or substantially different from the fourth angle β2 between the third portion 505c and the fourth portion 505d. In some embodiments, the third angle β1 and the fourth angle β2 are each less than or equal to about 90°. In some embodiments, the first portion 505a is substantially perpendicular to the second portion 505b, and the third portion 505c is substantially perpendicular to the fourth portion 505d.

[0064] In some embodiments, first inlet 504-1 and second inlet 504-2 communicate with first passageway 505-1 and second passageway 505-2, respectively. In some embodiments, the mixture can flow from first inlet 504-1 through first portion 505a and second portion 505b to mold cavity 503, and / or from second inlet 504-2 through third portion 505c and fourth portion 505d to mold cavity 503.

[0065] FIG. 35 is an exploded cross-sectional view of FIG. 30. In some embodiments, second mold 502 may be separated into multiple parts when molding apparatus 1001 is in an open configuration as shown in FIG. 35. In some embodiments, second mold 502 includes first part 502b, second part 502c, and third part 502e. First part 502b, second part 502c, and third part 502e are separable from one another. In some embodiments, first passageway 505-1 and second passageway 505-2 are formed when first part 502b, second part 502c, third part 502e, and first mold 501 engage with one another and when molding apparatus 1001 is in a closed configuration as shown in FIG. 35. FIG. 36 is a flowchart illustrating molding method 900 according to one embodiment of the present invention. In some embodiments, molding method 900 includes steps 901 through 908.

[0066] In some embodiments, molding method 900 includes step 901 of providing a molding apparatus 500 and an injection unit 506, as shown in FIG. 37. In some embodiments, injection unit 506 includes an injector 507 that holds and injects the mixture, and an outlet passage 508 that ejects the mixture from injector 507 out of injection unit 506. In some embodiments, molding apparatus 500 is similar to that described above or shown in any of FIGS. 7-11. In some embodiments, injection unit 506 is positioned above molding apparatus 500. Molding apparatus 500 is initially in an open configuration, as shown in FIG.

[0067] 38 , includes step 902 of engaging a discharge channel 508 of an injection unit 506 with a feed port 504 of a molding apparatus 500, and step 903 of engaging a first mold 501 with a second mold 502 of the molding apparatus 500. In some embodiments, step 902 precedes step 903, or vice versa. In some embodiments, the molding apparatus 500 is in a closed configuration after the first mold 501 engages with the second mold 502. In some embodiments, after the first mold 501 engages with the second mold 502, a mold cavity 503 is formed and is communicable with the passageway 505 and the feed port 504. The mixture can flow from the injection unit 506 through the feed port 504 and the passageway 505 into the mold cavity 503.

[0068] 39 , the molding method 900 includes a step 904 of injecting the mixture M′ into the mold cavity 503. The mixture M′ is injected into the mold cavity 503 from the injector 507 through the discharge passage 508, the supply port 504, and the passage 505. In some embodiments, the mixture M′ flows into the mold cavity 503 sequentially through the supply port 504, the first portion 505a, and the second portion 505b of the passage 505. In some embodiments, the mixture M′ enters the molding apparatus 500 through the supply port 504 and exits the molding apparatus 500 through an opening 503a that can communicate with the mold cavity 503. In some embodiments, the opening 503a is disposed in the inner wall 502f of the second mold 502, and the supply port 504 is disposed in the top surface 502a of the second mold 502. In some embodiments, the top surface 502a is substantially perpendicular to the inner wall 502f.

[0069] In some embodiments, after the mixture M′ is injected into the mold cavity 503, the mixture M′ undergoes a step 905 of physical foaming in the mold cavity 503 within the molding apparatus 500. After the physical foaming of the mixture M′, the mixture M′ becomes a foam member M in step 906. In some embodiments, the foam member M includes a main body portion M1 and remaining portions M2 and M3 protruding from the main body portion M1. In some embodiments, the dimensions of the main body portion M1 substantially correspond to the dimensions of the mold cavity 503, and the dimensions of the remaining portions M2 and M3 substantially correspond to the dimensions of the passage 505 and the feed port 504. In some embodiments, the remaining portions M2 and M3 include a first remaining portion M2 and a second remaining portion M3 connected to the first remaining portion M2. In some embodiments, the dimensions of the first remainder M2 substantially correspond to the dimensions of the first portion 505a and the dimensions of the feed port 504, and the dimensions of the second remainder M3 substantially correspond to the dimensions of the second portion 505b.

[0070] In some embodiments, the molding method 900 includes step 907 of separating the first mold 501 from the second mold 502 after forming the foam element M, as shown in Figure 40. The molding apparatus 500 is in an open configuration, as shown in Figure 40. In some embodiments, the molding method 900 includes step 908 of removing the foam element M from the mold cavity 503 after separating the first mold 501 from the second mold 502. In some embodiments, the discharge channel 508 is disengaged from the feed port 504 after the foam element M is formed or when the molding apparatus 500 is in an open configuration.

[0071] In some embodiments, when the molding apparatus 500 is in the open configuration shown in FIG. 41 , the second mold 502 of the molding apparatus 500 may be separated into multiple parts, similar to those described above or shown in FIG. 12 . In some embodiments, the second mold 502 includes a first part 502 b, a second part 502 c, and a third part 502 d, similar to those described above or shown in FIG. 12 . The first part 502 b, the second part 502 c, and the third part 502 d are separable from one another. After the foam member M is formed, the molding apparatus 500 is opened by separating the parts of the molding apparatus 500 from one another and separating the first mold 501 from the second mold 502, as shown in FIG. 41 . After the molding apparatus 500 is opened, the foam member M can be easily removed from the mold cavity 503.

[0072] In some embodiments, after the molding apparatus 500 is opened, the foam member M is removed as shown in FIG. 42. In some embodiments, the first remainder M2 and the second remainder M3 protrude from the main body M1. The second remainder M3 is connected to the main body M1, and the remainder M2 is connected to the second remainder M3. In some embodiments, the second remainder M3 tapers from the main body M1 toward the boundary between the first remainder M2 and the second remainder M3. In some embodiments, the first remainder M2 is strip-shaped or elongated.

[0073] Alternatively, in some embodiments, the first remainder portion M2 is separated from the main body portion M1 and the second remainder portion M3 when or after the molding apparatus 500 is opened, as shown in FIG. 43 . In some embodiments, the first remainder portion M2 is separated from the second remainder portion M3 when or after the molding apparatus 500 is opened. In some embodiments, the first remainder portion M2 is separated from the second remainder portion M3 by applying an external force (such as a pulling force that separates the first mold 501 from the second mold 502) to the first remainder portion M2 or the second remainder portion M3. In this manner, after the foam member M is formed, when the molding apparatus 500 is opened, the main body portion M1 remains in the mold cavity 503 and remains connected to the second remainder portion M3, and the first remainder portion M2 remains in the second mold 502 or the first portion 505a of the passageway 500. In some embodiments, the main body portion M1 and the second remainder portion M3 may be removed as shown in FIG.

[0074] After removing the foam member M as shown in FIG. 30 or 32, the remaining portions M2 and M3 are removed as shown in FIG. 45. In some embodiments, the remaining portions M2 and M3 are removed by cutting, trimming, grinding, or other suitable process. In some embodiments, the second remaining portion M3 is removed from the main body portion M1, resulting in the foam member M including the main body portion M1, as shown in FIG. 45. In some embodiments, after the second remaining portion M3 is removed, a trimming mark M4 is formed. In some embodiments, the trimming mark M4 is an area on the main body portion M1. In some embodiments, the trimming mark M4 is visible, i.e., the trimming mark M4 is visually distinct from the remainder of the main body portion M1 surrounding the trimming mark M4.

[0075] In some embodiments, the trimming marks M4 are located on a sidewall M8 of the body portion M1 that is substantially perpendicular to the top surface M6 and the bottom surface M7 of the body portion M1. In some embodiments, the top surface M6 is opposite the bottom surface M7.

[0076] In some embodiments, the remainder of the body portion M1 includes a skin layer, but the trimming mark M4 does not include a skin layer because the skin layer initially present at the trimming mark M4 is damaged or removed by the removal process. In some embodiments, the density of the remainder of the body portion M1 is substantially lower than the density of the trimming mark M4 due to incomplete physical foaming at the trimming mark M4. In other words, the degree of physical foaming at the trimming mark M4 is less than the degree of physical foaming at the remainder of the body portion M1. In some embodiments, the skin layer on the trimming mark M4 is damaged during the cutting process, so the trimming mark M4 has a higher ability to absorb liquids (e.g., water) than the remainder of the body portion M1. In some embodiments, the trimming mark M4 has a higher ability to absorb liquids (e.g., water) than the top surface M6 and bottom surface M7 of the body portion M1. In other words, liquids can easily enter the body portion M1 through the trimming mark M4 but cannot enter the body portion M1 through the top surface M6 and bottom surface M7. In some embodiments, the remainder of main body portion M1 is not liquid-absorbent, but trim mark M4 is liquid-absorbent. In some embodiments, trim mark M4 is surrounded by the remainder of side wall M8. In some embodiments, the remainder of side wall M8 is not liquid-absorbent, but trim mark M4 is liquid-absorbent. In some embodiments, trim mark M4 does not have a skin layer, and top surface M6, bottom surface M7, and the remainder of side wall M8 around trim mark M4 have a skin layer.

[0077] In some embodiments, the visible boundary line M5 is formed on the sidewall M8 of the main body portion M1 and surrounds the main body portion M1. In some embodiments, the visible boundary line M5 is a parting line of the molding apparatus 500 and corresponds to the junction of the first mold 501 and the second mold 502 that surround the mold cavity 503. In some embodiments, the foam element M, as shown in FIG. 45, is a component of a formed footwear article, such as an outsole.

[0078] Alternatively, in some embodiments, the molding apparatus 800 described above and shown in FIGS. 13-17 is used to perform the molding method 900, and after the molding apparatus 800 is opened, the foam member M is removed from the molding apparatus 800 as shown in FIG. 34. The foam member M shown in FIG. 40 is similar to the foam member M shown in FIG. 42. In some embodiments, the foam member M includes two first remainder portions M2 and two second remainder portions M3 protruding from a main body portion M1. In some embodiments, one of the first remainder portions M2 and one of the second remainder portions M3 connected to one of the first remainder portions M2 correspond to the first passage 505-1, and another of the first remainder portions M2 and another of the second remainder portions M3 connected to the other one of the first remainder portions M2 correspond to the second passage 505-2.

[0079] In some embodiments, the first remnant portion M2 is separated from the main body portion M1 and the second remnant portion M3 when or after the molding apparatus 800 is opened, similar to the process shown in Figure 43. In some embodiments, the main body portion M1 and the second remnant portion M3 may be removed as shown in Figure 47, similar to the foam member M shown in Figure 44. After removing the foam member M as shown in Figure 47 or Figure 46, the remnant portions M2 and M3 are removed as shown in Figure 48, similar to the foam member M shown in Figure 45, except that they have two trimming marks M4.

[0080] Alternatively, in some embodiments, the molding apparatus 700 described above and shown in Figures 19-22 is used to perform the molding method 700, and after the molding apparatus 700 is opened, the foam member M is removed from the molding apparatus 700 as shown in Figure 49. The foam member M shown in Figure 49 is similar to the foam member M shown in Figure 42. In some embodiments, the foam member M includes four first remainder portions M2 and four second remainder portions M3 protruding from a main body portion M1. In some embodiments, the first one of the first remainders M2 and the first one of the second remainders M3 connected to one of the first remainders M2 correspond to the first passage 505-1, the second one of the first remainders M2 and the second one of the second remainders M3 connected to the first one of the first remainders M2 correspond to the second passage 505-2, the third one of the first remainders M2 and the third one of the second remainders M3 connected to the third one of the first remainders M2 correspond to the third passage 505-3, and the fourth one of the first remainders M2 and the fourth one of the second remainders M3 connected to the fourth one of the first remainders M2 correspond to the fourth passage 505-4.

[0081] In some embodiments, the first remnant portion M2 is separated from the main body portion M1 and the second remnant portion M3 when or after the molding apparatus 700 is opened, similar to the process shown in Figure 43. In some embodiments, the main body portion M1 and the second remnant portion M3 may be removed as shown in Figure 50, similar to the foam member M shown in Figure 44. After removing the foam member M as shown in Figure 49 or 50, the remnant portions M2 and M3 are removed as shown in Figure 51, similar to the foam member M shown in Figure 45, except that they have four trimming marks M4.

[0082] In some embodiments, molding method 900 is performed by molding apparatus 1000, as shown in FIGS. 52-55. In some embodiments, injection unit 506 is positioned above molding apparatus 1000. Molding apparatus 1000 is initially in an open configuration, as shown in FIG. 52. In some embodiments, as shown in FIG. 53, discharge channel 508 of injection unit 506 engages with feed port 504 of molding apparatus 1000, and first mold 501 engages with second mold 502 of molding apparatus 1000. In some embodiments, mixture M' is injected into mold cavity 503, as shown in FIG. 54. In some embodiments, after mixture M' is injected into mold cavity 503, mixture M' undergoes physical foaming in mold cavity 503 within molding apparatus 1000.

[0083] After physical foaming of the mixture M', the mixture M' becomes a foam element M, as shown in FIG. 55. After the foam element M is formed, the molding apparatus 1000 is opened by separating the parts of the molding apparatus 1000 from each other and separating the first mold 501 from the second mold 502, as shown in FIG. 55. After the molding apparatus 1000 is opened, the foam element M can be easily removed from the mold cavity 503. The foam element M shown in FIG. 56 is similar to that shown in FIG. 42. In some embodiments, the remaining portions M2 and M3 are removed, as shown in FIGS. 57 and 58, similar to FIGS. 44 and 45, respectively. In some embodiments, a visible boundary line M5 is formed on the sidewall M8, and the trimming mark M4 is at or below the visible boundary line M5.

[0084] In some embodiments, molding method 900 is performed by molding apparatus 1001, as shown in Figures 59-62. In some embodiments, injection unit 506 is positioned above molding apparatus 1001. Molding apparatus 1001 is initially in an open configuration, as shown in Figure 59. In some embodiments, as shown in Figure 60, discharge channel 508 of injection unit 506 engages with supply port 504 of molding apparatus 1001, and first mold 501 engages with second mold 502 of molding apparatus 1001. In some embodiments, discharge channel 508-1 and discharge channel 508-2 engage with supply port 504-1 and supply port 504-2, respectively.

[0085] In some embodiments, the mixture M' is injected into the mold cavity 503, as shown in FIG. 61. The mixture M' flows from the discharge channel 508 through the feed port 504 into the mold cavity 503. In some embodiments, after the mixture M' is injected into the mold cavity 503, the mixture M' undergoes physical foaming in the mold cavity 503 within the molding apparatus 1001. After the physical foaming of the mixture M', the mixture M' becomes a foamed member M, as shown in FIG. 62. After the foamed member M is formed, the molding apparatus 1001 is opened by separating the parts of the molding apparatus 1001 from each other and separating the first mold 501 from the second mold 502, as shown in FIG. 62. After the molding apparatus 1001 is opened, the foamed member M can be easily removed from the mold cavity 503. The foamed member M shown in FIG. 63 is similar to that shown in FIG. 56. In some embodiments, remainders M2 and M3 are removed as shown in Figures 64 and 65, similar to Figures 57 and 58, respectively. In some embodiments, a visible boundary line M5 is formed on sidewall M8, and trim mark M4 is at or below visible boundary line M5.

[0086] The foregoing outlines features of several embodiments so that those skilled in the art may better understand the 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 those skilled in the art may make various changes, substitutions, and alterations therein without departing from the spirit and scope of the present disclosure.

[0087] 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 herein. As one skilled in the art will readily understand from this disclosure, 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 invention. Accordingly, it is intended that the appended claims include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Claims

1. a mold having a mold cavity; a supply port extending into the mold; a passage connected to the supply port and capable of communicating with the mold cavity; an opening communicating with the passage and capable of communicating with the mold cavity; A molding apparatus, wherein the supply port is located above the mold cavity and the opening is located to the side of the mold cavity.

2. 2. The molding apparatus of claim 1, wherein the mold includes a top surface above the mold cavity and an inner wall defining the mold cavity, the feed opening extending from the top surface toward the mold cavity.

3. The molding apparatus of claim 1 , wherein the passageway includes a first portion and a second portion connected to the first portion and disposed below the first portion.

4. 4. The molding apparatus of claim 3, wherein a first angle between the feed opening and the first portion is substantially greater than a second angle between the first portion and the second portion.

5. providing a mold having a mold cavity, a supply port extending into the mold and positioned above the mold cavity, a passageway connected to the supply port and capable of communicating with the mold cavity, and an opening located to the side of the mold cavity, connected to the passageway and capable of communicating with the mold cavity; injecting a mixture including a polymeric material and a blowing agent into the mold cavity; forming a foam element from the mixture by physical foaming; and removing the foam component from the mold cavity; The mixture flows from the feed port through the passage and the opening into the mold cavity.

6. 6. The method of claim 5, wherein the passage includes a first portion and a second portion connected to the first portion, the first portion connected to the supply port, and the second portion connected to the opening, and the mixture flows sequentially through the first portion and the second portion and vertically or diagonally along the first portion of the passage.

7. 6. The method of claim 5, wherein the foam member includes a main body portion corresponding to the mold cavity and a remainder portion protruding from the main body portion corresponding to the passage, the remainder portion being removed from the main body portion, and a trimming mark being formed and remaining in the main body portion after the remainder portion is removed.

8. a main body having a top surface, a bottom surface opposite the top surface, and a sidewall between the top surface and the bottom surface; a trimming mark disposed on a side wall of the main body portion, The foam member, wherein the trimming marks are visually distinct from the remainder of the body portion.

9. 9. The foam element of claim 8, wherein the trimming mark is liquid absorbent and the remainder of the main body is liquid non-absorbent, the trimming mark is free of a skin layer, and the skin layer is present on the top surface, the bottom surface, and the remainder of the sidewall around the trimming mark.

10. The foam element according to claim 8 , wherein the density of the remainder of the main body portion is substantially lower than the density of the trimming marks.

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