Injection molding apparatus, injection molding method, and articles formed thereby

Abstract

An injection molding apparatus for performing an injection molding process to form an article including one or more portions having different physical or functional properties is disclosed.SOLUTION: The molding method includes providing a molding apparatus including a first mold and a second mold, the first mold including a cooling mechanism embedded in the first mold, the second mold including a feed port extending through the second mold, engaging the first mold and the second mold to form a mold cavity defined by the first mold and the second mold, injecting a flowable material into the mold cavity through the feed port, activating the cooling mechanism to cool the flowable material around the cooling mechanism, and foaming the flowable material to obtain a foamed article.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Patent Application No. 19 / 087,570, filed March 23, 2025, and U.S. Provisional Patent Application No. 63 / 673,187, filed July 19, 2024, both of which are incorporated by reference in their entireties.

[0002] Technical Field The present disclosure discloses an injection molding apparatus, an injection molding method, and an article formed thereby, and in particular an injection molding apparatus for performing an injection molding method to form an article including one or more portions having different physical or functional properties. [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 under force or pressure into a mold cavity, where the mixture foams and cools to form the foamed article.

[0004] However, there is a need for improved foam article properties, such as different properties in different portions of a foam article produced by an injection molding system. Accordingly, there is a need for improved injection molding system designs and methods for producing foam articles. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] U.S. Patent Application Serial No. 19 / 087,570 [Patent Document 2] U.S. Provisional Patent Application No. 63 / 673,187 Summary of the Invention

[0006] The present disclosure discloses an injection molding apparatus, an injection molding method, and articles formed thereby.

[0007] According to one embodiment of the present disclosure, there is provided a molding method, the molding method including the steps of: providing a molding apparatus including a first mold and a second mold, where the first mold includes a recess recessed therein and the second mold includes a feed port extending therethrough, engaging the first mold and the second mold to form a mold cavity defined by the first mold and the second mold and capable of communicating with the recess and the feed port, injecting a flowable material through the feed port into the mold cavity to fill the recess and the mold cavity, and foaming the flowable material to obtain a foamed article.

[0008] According to one embodiment of the present disclosure, there is provided a molding method, the molding method including the steps of: providing a molding apparatus including a first mold and a second mold, the first mold including a cooling mechanism embedded therein and the second mold including a feed port extending therethrough, engaging the first mold and the second mold to form a mold cavity defined by the first mold and the second mold, injecting a flowable material through the feed port into the mold cavity, operating the cooling mechanism to cool the flowable material around the cooling mechanism, and foaming the flowable material to obtain a foamed article.

[0009] According to one embodiment of the present disclosure, a foam article is provided. The foam article includes a first surface, a second surface opposite the first surface, and a third surface between the first and second surfaces. The foam article includes a first trace and a second trace. The first trace is disposed on the first surface. The second trace is disposed on the second surface, opposite the first trace, and perpendicularly aligned with the first trace. [Brief explanation of the drawings]

[0010] 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;

[0011] [Figure 1] FIG. 1 is a schematic diagram of an injection molding apparatus in an open configuration according to one embodiment of the present disclosure. [Figure 2] FIG. 1 is a schematic diagram of an injection molding apparatus in a closed configuration according to one embodiment of the present disclosure. [Figure 3] 1 is a schematic cross-sectional view illustrating engagement between an injection device and a feed port according to an embodiment of the present disclosure. [Figure 4] 1 is a schematic cross-sectional view illustrating the injection of flowable material from an injection device through an outlet and a feed port into a mold cavity according to one embodiment of the present disclosure. [Figure 5] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 6] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 7] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 8] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 9] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 10] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 11] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 12] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 13] FIG. 1 is a schematic diagram of an injection molding apparatus according to an embodiment of the present disclosure. [Figure 14]1 is a schematic cross-sectional view illustrating engagement between an injection device and a feed port according to an embodiment of the present disclosure. [Figure 15] 1 is a schematic cross-sectional view illustrating engagement of multiple jetting devices with a feed port according to an embodiment of the present disclosure. [Figure 16] 1 is a schematic cross-sectional view illustrating the injection of flowable material from an injection device through an outlet and a feed port into a mold cavity according to one embodiment of the present disclosure. [Figure 17] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 18] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 19] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 20] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 21] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 22] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 23] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 24] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 25] FIG. 1 is a schematic diagram of an injection molding apparatus according to an embodiment of the present disclosure. [Figure 26] 26 is a schematic cross-sectional top view of the injection molding apparatus taken along line CC' in FIG. 25. [Figure 27] 1 is a schematic cross-sectional view illustrating engagement between an injection device and a feed port according to an embodiment of the present disclosure. [Figure 28] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 29] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 30]FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 31] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 32] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 33] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 34] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 35] FIG. 1 is a schematic diagram of an injection molding apparatus according to an embodiment of the present disclosure. [Figure 36] FIG. 36 is a schematic cross-sectional top view of the first mold taken along line DD′ in FIG. 35. [Figure 37] FIG. 36 is a schematic cross-sectional top view of the second mold taken along line EE' in FIG. 35. [Figure 38] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 39] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 40] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 41] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 42] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 43] FIG. 1 is a schematic diagram of an injection molding apparatus according to an embodiment of the present disclosure. [Figure 44] FIG. 44 is a schematic cross-sectional top view of the first mold taken along line FF' in FIG. 43. [Figure 45] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 46] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 47] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 48]1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 49] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 50] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 51] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 52] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 53] FIG. 1 is a schematic diagram of an injection molding apparatus according to an embodiment of the present disclosure. [Figure 54] FIG. 1 is a schematic diagram of an injection molding apparatus according to an embodiment of the present disclosure. [Figure 55] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 56] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 57] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 58] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 59] FIG. 1 is a schematic diagram of an injection molding apparatus according to an embodiment of the present disclosure. [Figure 60] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 61] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 62] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 63] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 64] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 65] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 66] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 67] FIG. 1 is a schematic diagram of an injection molding apparatus according to an embodiment of the present disclosure. [Figure 68] 68 is a schematic top cross-sectional view of the injection molding apparatus taken along line GG' in FIG. 67. [Figure 69] 1 is a schematic cross-sectional view illustrating engagement between an injection device and a feed port according to an embodiment of the present disclosure. [Figure 70] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 71] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 72] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 73] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 74] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 75] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 76] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 77] FIG. 1 is a schematic diagram of an injection molding apparatus according to an embodiment of the present disclosure. [Figure 78] 78 is a schematic cross-sectional top view of the injection molding apparatus taken along line HH' in FIG. 77. [Figure 79] 1 is a schematic cross-sectional view illustrating engagement between an injection device and a feed port according to an embodiment of the present disclosure. [Figure 80] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 81] 1A-1D are schematic cross-sectional views illustrating exemplary stages of an injection molding method according to one embodiment of the present disclosure. [Figure 82]FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 83] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 84] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. [Figure 85] FIG. 1 is a schematic diagram illustrating a foam article according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0012] 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.

[0013] 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.

[0014] 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.

[0015] In some embodiments, a first injection molding apparatus 100 is shown in FIG. 1 in an open configuration. In some embodiments, the first injection molding apparatus 100 is configured to form a foam article. The first injection molding apparatus 100 includes a first mold 101 and a second mold 102 that is engageable with the first mold 101. In some embodiments, the first mold 101 is positioned below the second mold 102. In some embodiments, the first mold 101 is a lower mold and the second mold 102 is an upper mold. The first injection molding apparatus 100 includes a feed port 104 configured to allow a flowable material to pass through. In some embodiments, the feed port 104 is positioned in the first mold 101 or the second mold 102. While FIG. 1 illustrates the feed port 104 in the second mold 102, it should be understood that this is not limiting. In some embodiments, the first injection molding apparatus 100 includes a well 105 recessed in the first mold 101 or the second mold 102. FIG. 1 illustrates well 105 being disposed in and recessed into first mold 101, but it should be understood that this is not limiting. In some embodiments, well 105 is configured to temporarily hold a material. In some embodiments, well 105 is a cold slug, cold well, or the like. In some embodiments, width W1 of inlet 104 is substantially different from or the same as width W2 of well 105. In some embodiments, width W1 is substantially greater than or less than width W2. In some embodiments, the ratio of width W2 to height H2 of well 105 is about 1:1 to about 1:1.5. In some embodiments, width W2 is about 5 mm to about 10 mm.

[0016] 2 shows a first injection molding apparatus in a closed configuration in which a first mold 101 engages a second mold 102. In some embodiments, a mold cavity 103 is formed when the first injection molding apparatus 100 is in the closed configuration. The mold cavity 103 is configured to hold a material. A feed port 104 is communicable with the mold cavity 103. In some embodiments, the feed port 104 is vertically aligned with a well 105 when the first injection molding apparatus 100 is in the closed configuration.

[0017] In some embodiments, the injection molding method includes several steps illustrated in Figures 1 to 12. A first injection molding apparatus 100 is configured to perform the injection molding method.

[0018] The injection molding method includes providing a first injection molding apparatus 100 including a first mold 101 and a second mold 102, as shown in FIG. 1 , and engaging the first mold 101 with the second mold 102, as shown in FIG. 2 . In some embodiments, the injection molding method includes engaging an injection apparatus 108 with a feed port 104, as shown in FIG. 3 . In some embodiments, the injection apparatus 108 engages with the feed port 104 before or after the first mold 101 and the second mold 102 are engaged. In some embodiments, the outlet 108 a of the injection apparatus 108 engages with the feed port 104 before or after the first mold 101 and the second mold 102 are engaged. In some embodiments, the injection apparatus 108 is configured to inject a flowable material into the mold cavity 103 through the outlet 108 a and the feed port 104. In some embodiments, the injection apparatus 108 is connected to a mixing unit configured to mix a polymeric material and a blowing agent. In some embodiments, the flowable material is a mixture of a polymeric material (such as polyurethane (PU), thermoplastic polyurethane (TPU)) and a foaming agent (such as a physical foaming agent, e.g., carbon dioxide, nitrogen, supercritical fluid, etc.). The mixture is foamable or microfoamable. The mixture can undergo a physical foaming process in the mold cavity 103. The mixture in the mold cavity 103 becomes a foamed article after the physical foaming process.

[0019] The injection molding method includes injecting a flowable material into a first injection molding apparatus 100. FIG. 4 illustrates flowable material 106' being injected from injection apparatus 108 through outlet 108a and feed port 104 into mold cavity 103. In some embodiments, the flow of flowable material 106' is illustrated in FIGS. 5-7. In some embodiments, when flowable material 106' is injected from outlet 108a of injection apparatus 108, flowable material 106' flows through feed port 104 and mold cavity 103 toward well 105, as shown by arrow A in FIG. 5. Thus, a portion of flowable material 106' is disposed within well 105. Then, flowable material 106' continues to flow toward two sidewalls of mold cavity 103, as shown by arrow B in FIG. 6. In some embodiments, after the flowable material 106' fills the well 105, the flowable material 106' continues to flow toward the two side walls of the mold cavity 103. In some embodiments, the flowable material 106' finally fills the mold cavity 103, as shown in Figure 7. After injection of the flowable material 106', the flowable material 106' undergoes physical foaming within the mold cavity 103 to become the foamed article 106, as shown in Figure 4.

[0020] The injection molding method includes disengaging the first mold 101 from the second mold 102 and opening the first injection molding apparatus 100. Figure 8 illustrates opening the first injection molding apparatus 100 after the foam article 106 has been formed. In some embodiments, the outlet 108a of the injection apparatus 108 engages with the feed port 104 before or after the first mold 101 and the second mold 102 have disengaged. After opening the first injection molding apparatus 100, the foam article 106 is removed from the first injection molding apparatus 100, as shown in Figures 8 and 9.

[0021] The injection molding method includes forming an article by a foaming process. Figure 9 shows a foam article 106 formed by a first injection molding apparatus 100. In some embodiments, the foam article 106 includes a first protrusion 107 and a second protrusion 109. In some embodiments, the first protrusion 107 is perpendicularly aligned with the second protrusion 109. In some embodiments, the first protrusion 107 corresponds to and is complementary to at least a portion of the well 105, and the second protrusion 109 corresponds to and is complementary to at least a portion of the feed opening 104.

[0022] In some embodiments, first protrusion 107 and second protrusion 109 are removed, as shown in FIGS. 10-12. FIG. 10 is a schematic side view of foam article 106, FIG. 11 is a schematic bottom view of foam article 106, and FIG. 12 is a schematic top view of foam article 106. In some embodiments, first protrusion 107 and second protrusion 109 are removed by cutting, trimming, grinding, or any other suitable process. As a result, first trimming trace 107' is formed on the bottom surface of foam article 106, and second trimming trace 109' is formed on the top surface of foam article 106. In some embodiments, first trimming trace 107' and second trimming trace 109' do not include the skin layer because the skin layer is damaged or removed by the trimming process. In some embodiments, foam article 106 is a component of a footwear article, such as an outsole.

[0023] 5, the flowable material 106' first flows into and fills the well 105 and then fills the mold cavity 103, resulting in no or minimal flow marks surrounding the first protrusion 107 and disposed on the top surface of the foamed article 106. Furthermore, the flowable material 106' in the first injection molding apparatus 100 has undergone uniform foaming, resulting in more evenly distributed voids in the foamed article 106 and a more uniform overall density for the foamed article 106.

[0024] Alternatively, as shown in Figures 13-24, a second injection molding apparatus 200 is used. In some embodiments, the second injection molding apparatus 200 is similar to the first injection molding apparatus 100 except for the number of wells 105 and feed ports 104. As shown in Figure 13, in some embodiments, the second injection molding apparatus 200 includes several wells 105 and several feed ports 104 corresponding to the wells 105. In some embodiments, each well 105 corresponds to one feed port 104. In some embodiments, each well 105 is vertically aligned with a corresponding feed port 104.

[0025] 14 shows that the injection device 108 engages with the second injection molding device 200. In some embodiments, the injection device 108 engages with the feed ports 104 before or after the first mold 101 and the second mold 102 are engaged. In some embodiments, the injection device 108 includes several outlets 108a that are engageable with one of the feed ports 104. Alternatively, as shown in FIG. 15, several injection devices 108 engage with the second injection molding device 200. In some embodiments, each injection device 108 has an outlet 108a that is engageable with the feed port 104.

[0026] For simplicity and clarity, the injection unit 108 engaged with the second injection molding apparatus 200 is shown in subsequent figures to illustrate the subsequent steps, however, it should be understood that the injection unit 108 in Figure 14 can perform the subsequent steps in a similar manner.

[0027] After the injection device 108 is engaged with the second injection molding device 200, the flowable material 106' is injected from the injection device 108 through the outlet 108a and the feed port 104 into the mold cavity 103, as shown in FIG. 16. In some embodiments, the flow of the flowable material 106' is shown in FIGS. 17-19. In some embodiments, when the flowable material 106' is injected from the outlet 108a of the injection device 108, the flowable material 106' flows through the feed port 104 and the mold cavity 103 toward the well 105, as shown by arrow A in FIG. 17, in a manner similar to that described above or shown in FIG. 5. Thus, a portion of the flowable material 106' is disposed within the well 105. The flowable material 106' then continues to flow toward the two sidewalls of the mold cavity 103, as shown by arrow B in FIG. 18, in a manner similar to that described above or shown in FIG. 6. In some embodiments, the flowable material 106' finally fills the mold cavity 103, as shown in Figure 19. After injection of the flowable material 106', the flowable material 106' undergoes physical foaming within the mold cavity 103 to become the foamed article 106, as shown in Figure 16.

[0028] After foam article 106 is formed, second injection molding apparatus 200 is opened to remove foam article 106, as shown in Figure 20, in a manner similar to that described above or shown in Figure 8. Foam article 106 formed by second injection molding apparatus 200, as shown in Figure 21, is similar to foam article 106 described above or shown in Figure 9. In some embodiments, as shown in Figures 22-24, first protrusion 107 and second protrusion 109 are removed, as shown in a manner similar to that described above or shown in Figures 10-12. Figure 22 is a schematic side view of foam article 106, Figure 23 is a schematic bottom view of foam article 106, and Figure 24 is a schematic top view of foam article 106.

[0029] In some embodiments, a third injection molding apparatus 300 is used to implement another injection molding method having several steps shown in FIGS. 25-34. FIG. 25 shows the third injection molding apparatus 300 in an open configuration. In some embodiments, the third injection molding apparatus 300 includes a first mold 101, a second mold 102, and a feed port 104 similar to those in the first injection molding apparatus 100 or the second injection molding apparatus 200. While FIG. 25 shows only one feed port 104, it should be understood that more than one feed port 104 may be included. In some embodiments, the third injection molding apparatus 300 includes several recesses 110 recessed into the first mold 101 or the second mold 102. While FIG. 25 shows the recesses 110 (having a width W3 and a height H3) disposed in and recessed into the first mold 101, it should be understood that this is not limiting. In some embodiments, the recesses 110 are configured to temporarily hold material. Figure 26 is a schematic top cross-sectional view of the third injection molding apparatus 300 taken along line CC' in Figure 25. In some embodiments, the recesses 110 are arranged in a predetermined pattern or randomly. In some embodiments, the recesses 110 are arranged adjacent to one side (e.g., left side, right side, front, rear, etc.) of the third injection molding apparatus 300.

[0030] 27 shows third injection molding apparatus 300 in a closed configuration in which first mold 101 engages second mold 102. In some embodiments, mold cavity 103 is formed when third injection molding apparatus 300 is in the closed configuration. In some embodiments, injection apparatus 108 engages third injection molding apparatus 300 before or after closing of third injection molding apparatus 300. In some embodiments, outlet 108a of injection apparatus 108 engages feed port 104 such that flowable material can flow from injection apparatus 108 through outlet 108a and feed port 104 into mold cavity 103.

[0031] After the injection device 108 is engaged, the flowable material 106' flows into the mold cavity 103, as shown in FIG. 28. In some embodiments, the flowable material 106' fills the recess 110. In some embodiments, the flowable material 106' is a mixture of a polymeric material (such as polyurethane (PU), thermoplastic polyurethane (TPU)) and a foaming agent (a physical foaming agent, e.g., carbon dioxide, nitrogen, supercritical fluid, etc.). The mixture is foamable or micro-foamable. The mixture can undergo a physical foaming process in the mold cavity 103. The mixture in the mold cavity 103 becomes a foamed article after the physical foaming process.

[0032] 29 illustrates opening the third injection molding apparatus 300 after the foam article 106 is formed. In some embodiments, the outlet 108a of the injection apparatus 108 engages the feed throat 104 before or after the first mold 101 and second mold 102 disengage. After the first injection molding apparatus 100 is opened, the foam article 106 is removed from the third injection molding apparatus 300, as shown in FIGS. 29 and 30.

[0033] 30 and 31 show foam article 106 formed by third injection molding apparatus 300. FIG. 30 is a schematic side view of foam article 106, and FIG. 31 is a schematic perspective view of foam article 106. In some embodiments, foam article 106 includes second protrusion 109 and third protrusion 111. In some embodiments, second protrusion 109 corresponds to and is complementary to at least a portion of feed port 104, and third protrusion 111 corresponds to and is complementary to at least a portion of recess 110.

[0034] In some embodiments, second protrusion 109 and third protrusion 111 are removed, as shown in FIGS. 32-34 . FIG. 32 is a schematic side view of foam article 106, FIG. 33 is a schematic top view of foam article 106, and FIG. 34 is a schematic bottom view of foam article 106. In some embodiments, second protrusion 109 and third protrusion 111 are removed by cutting, trimming, grinding, or any other suitable process. As a result, second trimming mark 109′ is formed on the top surface of foam article 106, and third trimming mark 111′ is formed on the bottom surface of foam article 106. In some embodiments, second trimming mark 109′ and third trimming mark 111′ do not include a skin layer because the skin layer is damaged or removed by the trimming process. In some embodiments, foam article 106 is a component of a footwear article, such as an outsole. Because the flowable material 106' first flows into and fills the recesses 110 and then fills the mold cavity 103, there is no or minimal flow marks on the surface of the foamed article 106. Furthermore, the flowable material 106' in the third injection molding apparatus 300 is undergoing uniform foaming, which results in more evenly distributed voids within the foamed article 106 and a more uniform overall density for the foamed article 106.

[0035] Alternatively, as shown in Figures 35-42, a fourth injection molding apparatus 400 is used. In some embodiments, the fourth injection molding apparatus 400 is similar to the third injection molding apparatus 300, except that the recess 110 is also disposed in the second mold 102. Figure 35 is a schematic side view of the fourth injection molding apparatus 400, Figure 36 is a schematic top cross-sectional view of the first mold 101 taken along line DD' in Figure 35, and Figure 37 is a schematic top cross-sectional view of the second mold 102 taken along line EE' in Figure 35.

[0036] After the flowable material 106′ enters the mold cavity 103 of the fourth injection molding apparatus 400, the flowable material 106′ undergoes physical foaming to become the foamed article 106, as shown in FIGS. 38 and 39 . FIG. 38 is a schematic side view of the foamed article 106, and FIG. 39 is a schematic perspective view of the foamed article 106. In some embodiments, the foamed article 106 includes a second protrusion 109 and a third protrusion 111. In some embodiments, the second protrusion 109 and some of the third protrusions 111 are on the top surface of the foamed article 106. In some embodiments, some of the third protrusions 111 are on the bottom surface of the foamed article 106. In some embodiments, some of the third protrusions 111 are on the side surface of the foamed article 106. In some embodiments, the number of third protrusions 111 is different from the number of second protrusions 109. In some embodiments, the number of third protrusions 111 is greater than the number of second protrusions 109. In some embodiments, the number of third protrusions 111 is equal to or less than 3. In some embodiments, the number of third protrusions 111 is equal to 1, 2, or 3.

[0037] In some embodiments, second protrusion 109 and third protrusion 111 are removed, as shown in FIGS. 40-42. FIG. 40 is a schematic side view of foam article 106, FIG. 41 is a schematic top view of foam article 106, and FIG. 42 is a schematic bottom view of foam article 106. In some embodiments, second protrusion 109 and third protrusion 111 are removed by cutting, trimming, grinding, or any other suitable process. As a result, second trimming mark 109' is formed on the top surface of foam article 106, and third trimming mark 111' is formed on the bottom surface of foam article 106. In some embodiments, third protrusion 111 and second protrusion 109 are removed to form third trimming mark 111' and second trimming mark 109'. In some embodiments, the surface area of ​​each of third trimming marks 111' is substantially smaller than the surface area of ​​second trimming mark 109'.

[0038] In some embodiments, a fifth injection molding apparatus 500 is used to implement another injection molding method having several steps shown in Figures 43-52. In some embodiments, the fifth injection molding apparatus 500 is similar to the third injection molding apparatus 300 and the first injection molding apparatus 100, or the fifth injection molding apparatus 500 is a hybrid between the third injection molding apparatus 300 and the first injection molding apparatus 100. Figure 43 is a schematic side view of the fifth injection molding apparatus 500, and Figure 44 is a schematic top cross-sectional view of the first mold 101 taken along line FF' in Figure 43. In some embodiments, the first mold 101 includes a well 105 and several recesses 110, and the second mold 102 includes a feed port 104 that is aligned perpendicular to the well 105.

[0039] In some embodiments, after closing the fifth injection molding apparatus 500 and engaging the injection apparatus 108 with the fifth injection molding apparatus 500 as shown in FIG. 43, the flowable material 106' flows from the injection apparatus 108 into the mold cavity 103 as shown in FIG. 45. In some embodiments, the flow of the flowable material 106' is shown in FIGS. 46-48. In some embodiments, when the flowable material 106' is injected from the outlet 108a of the injection apparatus 108, the flowable material 106' flows through the feed port 104 and the mold cavity 103 toward the well 105, as shown by arrow A in FIG. 46, in a manner similar to that described above or shown in FIG. 5. Thus, a portion of the flowable material 106' is disposed within the well 105. The flowable material 106' then continues to flow toward the two sidewalls of the mold cavity 103, as shown by arrow B in FIG. 47, in a manner similar to that described above or shown in FIG. 6. In some embodiments, the flowable material 106' finally fills the mold cavity 103, as shown in Figure 48. After injection of the flowable material 106', the flowable material 106' undergoes physical foaming within the mold cavity 103 to become the foamed article 106, as shown in Figures 45 and 49. Figure 49 is a schematic side view of the foamed article 106. In some embodiments, the foamed article 106 includes a first protrusion 107, a second protrusion 109, and a third protrusion 111. In some embodiments, the first protrusion 107 and the third protrusion 111 are located on the bottom surface of the foamed article 106, and the second protrusion 109 is located on the top surface of the foamed article 106.

[0040] In some embodiments, first protrusion 107, second protrusion 109, and third protrusion 111 are removed, as shown in Figures 50-52. Figure 50 is a schematic side view of foam article 106, Figure 51 is a schematic top view of foam article 106, and Figure 52 is a schematic bottom view of foam article 106. In some embodiments, first protrusion 107, second protrusion 109, and third protrusion 111 are removed by cutting, trimming, grinding, or any other suitable process. As a result, second trimming mark 109' is formed on the top surface of foam article 106, and first trimming mark 107' and third trimming mark 111' are formed on the bottom surface of foam article 106.

[0041] In some embodiments, a sixth injection molding apparatus 600 is used to implement another injection molding method having several steps illustrated in FIGS. 53-58. FIG. 53 illustrates the sixth injection molding apparatus 600 in an open configuration. The sixth injection molding apparatus 600 includes a first mold 101 and a second mold 102 engageable with the first mold 101. The sixth injection molding apparatus 600 includes a feed port 104 configured to allow a flowable material to pass therethrough. In some embodiments, the feed port 104 is located in the first mold 101 or the second mold 102. In some embodiments, the sixth injection molding apparatus 600 includes a cooling mechanism 601 located in the first mold 101 or the second mold 102. While FIG. 53 illustrates that the cooling mechanism 601 is located in the first mold 101, it should be understood that this is not a limitation. Furthermore, while only one cooling mechanism 601 is located in the sixth injection molding apparatus 600, it should be understood that the number of cooling mechanisms 601 is not limited.

[0042] In some embodiments, cooling mechanism 601 is configured to cool a portion of the flowable material as it is disposed on or on first mold 101. In some embodiments, cooling mechanism 601 allows a liquid (coolant, water, etc.) to flow or circulate therethrough to cool a portion of first mold 101 or a portion of the flowable material disposed on or on first mold 101. In some embodiments, cooling mechanism 601 is an electric cooler, a chiller, etc.

[0043] FIG. 54 shows the sixth injection molding apparatus 600 in a closed configuration in which the first mold 101 engages the second mold 102. In some embodiments, a mold cavity 103 is formed when the sixth injection molding apparatus 600 is in the closed configuration. The mold cavity 103 is configured to hold a material. A feed port 104 is communicable with the mold cavity 103. In some embodiments, the injection apparatus 108 engages the feed port 104 before or after the first mold 101 and the second mold 102 engage. In some embodiments, the outlet 108a of the injection apparatus 108 engages the feed port 104 before or after the first mold 101 and the second mold 102 engage. In some embodiments, the injection apparatus 108 is configured to inject flowable material into the mold cavity 103 through the outlet 108a and the feed port 104. In some embodiments, the flowable material is a mixture of a polymeric material (such as polyurethane (PU), thermoplastic polyurethane (TPU)) and a foaming agent (such as a physical foaming agent, e.g., carbon dioxide, nitrogen, supercritical fluid, etc.). The mixture is foamable or microfoamable. The mixture can undergo a physical foaming process in the mold cavity 103. The mixture in the mold cavity 103 becomes a foamed article after the physical foaming process.

[0044] FIG. 55 illustrates the injection of flowable material 106′ from injection apparatus 108 through outlet 108a and feed port 104 into mold cavity 103. In some embodiments, prior to or during injection of flowable material 106′ into mold cavity 103, the temperature of sixth injection molding apparatus 600 is elevated prior to injection of flowable material 106′ and maintained at a first predetermined temperature during injection of flowable material 106′ to promote flow of flowable material 106′ into mold cavity 103. In some embodiments, the first predetermined temperature is between about 30° C. and about 40° C. In some embodiments, after injection of flowable material 106′, flowable material 106′ in mold cavity 103 is at a temperature substantially equal to the first predetermined temperature.

[0045] After injection of the flowable material 106', the flowable material 106' undergoes physical foaming within the mold cavity 103 to become the foamed article 106, as shown in FIG. 56 . In some embodiments, after injection of the flowable material 106' and while the flowable material 106' is foaming within the mold cavity 103, the cooling mechanism 601 operates to cool the flowable material 106' around the cooling mechanism 601. In some embodiments, the cooling mechanism 601 operates to cool the flowable material 106' from a first predetermined temperature to a second predetermined temperature. In some embodiments, the second predetermined temperature is substantially less than 25° C. In some embodiments, the second predetermined temperature is about 20° C. In some embodiments, the time required for the cooling mechanism 601 to cool the flowable material 106' around the cooling mechanism 601 from the first predetermined temperature to the second predetermined temperature is substantially less than 2 seconds.

[0046] After cooling of flowable material 106' by cooling mechanism 601 and foaming of flowable material 106', a foam article having a skin layer 602 is formed. Skin layer 602 is formed from flowable material 106' around cooling mechanism 601. In some embodiments, skin layer 602 has a thickness of about 0.5 mm to about 5 mm. In some embodiments, a density gradient exists in skin layer 602, where the density of skin layer 602 gradually increases from the interior of foam article 106 to the exterior of foam article 106. In some embodiments, skin layer 602 has a lower degree of physical foaming than the remainder of foam article 106. That is, the remainder of foam article 106 has a higher degree of physical foaming than skin layer 602. In some embodiments, the density of skin layer 602 is different from the density of the remainder of foam article 106. In some embodiments, the density of skin layer 602 is substantially higher than the density of the remainder of foam article 106. In some embodiments, the density of the skin layer 602 is substantially 0.2 g / cm 3 or greater, and the density of the remainder of the foam article 106 is substantially 0.2 g / cm 3 In some embodiments, the density of the skin layer 602 is substantially less than 0.22 g / cm 3 or greater, and the density of the remainder of the foam article 106 is substantially 0.16 g / cm 3In some embodiments, the abrasion resistance of the skin layer 602 is greater than the abrasion resistance of the remainder of the foam article 106 because the density of the skin layer 602 is greater than the density of the remainder of the foam article 106.

[0047] Figure 57 illustrates opening the sixth injection molding apparatus 600 after forming the foam article 106 having the skin layer 602. In some embodiments, the outlet 108a of the injection apparatus 108 engages with the feed port 104 before or after the first mold 101 and the second mold 102 disengage. After opening the sixth injection molding apparatus 600, the foam article 106 having the skin layer 602 is removed from the sixth injection molding apparatus 600, as shown in Figure 57. In some embodiments, the second protrusion 109 is removed by cutting, trimming, grinding, or any other suitable process, as shown in Figure 58.

[0048] In some embodiments, the foam article 106 is a component of an article of footwear, such as an outsole. In some embodiments, the skin layer 602 is exposed to the surroundings, with no adhesive or other components covering the skin layer 602.

[0049] In some embodiments, seventh injection molding apparatus 700 is used to implement another injection molding method having several steps shown in Figures 59-66. In some embodiments, seventh injection molding apparatus 700 is similar to first injection molding apparatus 100 and sixth injection molding apparatus 600, or seventh injection molding apparatus 700 is a hybrid of first injection molding apparatus 100 and sixth injection molding apparatus 600. Figure 59 is a schematic side view of seventh injection molding apparatus 700 in a closed configuration. In some embodiments, first mold 101 includes well 105 and cooling mechanism 601, and second mold 102 includes feed port 104 vertically aligned with well 105.

[0050] In some embodiments, prior to or during injection of flowable material 106′ into mold cavity 103, the temperature of seventh injection molding apparatus 700 is elevated prior to injection of flowable material 106′ and maintained at a first predetermined temperature during injection of flowable material 106′ to promote flow of flowable material 106′ into mold cavity 103. In some embodiments, the first predetermined temperature is between about 30° C. and about 40° C. In some embodiments, after injection of flowable material 106′, flowable material 106′ in mold cavity 103 is at a temperature substantially equal to the first predetermined temperature.

[0051] In some embodiments, after closing the seventh injection molding apparatus 700 and engaging the injection apparatus 108 with the seventh injection molding apparatus 700 as shown in FIG. 59, the flowable material 106' flows from the injection apparatus 108 into the mold cavity 103 as shown in FIG. 60. In some embodiments, the flow of the flowable material 106' is shown in FIGS. 61-63. In some embodiments, when the flowable material 106' is injected from the outlet 108a of the injection apparatus 108, the flowable material 106' flows through the feed port 104 and the mold cavity 103 toward the well 105, as shown by arrow A in FIG. 61, in a manner similar to that described above or shown in FIG. 5. Thus, a portion of the flowable material 106' is disposed within the well 105. The flowable material 106' then continues to flow toward the two sidewalls of the mold cavity 103, as shown by arrow B in FIG. 62, in a manner similar to that described above or shown in FIG. 6. In some embodiments, the flowable material 106' fills the mold cavity 103 last, as shown in FIG.

[0052] In some embodiments, after injection of the flowable material 106′ and during foaming of the flowable material 106′ within the mold cavity 103, the cooling mechanism 601 operates as shown in FIG. 64 . The cooling mechanism 601 operates to cool the flowable material 106′ around the cooling mechanism 601. In some embodiments, the cooling mechanism 601 operates to cool the flowable material 106′ from a first predetermined temperature to a second predetermined temperature. In some embodiments, the second predetermined temperature is substantially less than 25° C. In some embodiments, the second predetermined temperature is about 20° C. In some embodiments, the time required for the cooling mechanism 601 to cool the flowable material 106′ around the cooling mechanism 601 from the first predetermined temperature to the second predetermined temperature is substantially less than 2 seconds.

[0053] After foaming and cooling of the flowable material 106', a foam article 106 having a skin layer 602 is formed, as shown in FIG. 60. The skin layer 602 is formed from the flowable material 106' around the cooling mechanism 601. In some embodiments, the skin layer 602 has a thickness of about 0.5 mm to about 5 mm. In some embodiments, a density gradient exists in the skin layer 602, where the density of the skin layer 602 gradually increases from the interior of the foam article 106 to the exterior of the foam article 106. In some embodiments, the skin layer 602 has a lower degree of physical foaming than the remainder of the foam article 106. That is, the remainder of the foam article 106 has a higher degree of physical foaming than the skin layer 602. In some embodiments, the density of the skin layer 602 is different from the density of the remainder of the foam article 106. In some embodiments, the density of the skin layer 602 is substantially higher than the density of the remainder of the foam article 106. In some embodiments, the density of the skin layer 602 is substantially 0.2 g / cm. 3 or greater, and the density of the remainder of the foam article 106 is substantially 0.2 g / cm 3 In some embodiments, the density of the skin layer 602 is substantially less than 0.22 g / cm 3 or greater, and the density of the remainder of the foam article 106 is substantially 0.16 g / cm 3In some embodiments, the abrasion resistance of the skin layer 602 is greater than the abrasion resistance of the remainder of the foam article 106 because the density of the skin layer 602 is greater than the density of the remainder of the foam article 106.

[0054] FIG. 65 illustrates opening the seventh injection molding apparatus 700 after forming the foam article 106 having the skin layer 602. In some embodiments, the outlet 108a of the injection apparatus 108 engages with the feed port 104 before or after the first mold 101 and the second mold 102 disengage. After opening the seventh injection molding apparatus 700, the foam article 106 having the skin layer 602 is removed from the seventh injection molding apparatus 700, as shown in FIG. 65. In some embodiments, the first protrusion 107 and the second protrusion 109 are removed by cutting, trimming, grinding, or any other suitable process, as shown in FIG. 66. In some embodiments, the foam article 106 is a component of a footwear article, such as an outsole. In some embodiments, the skin layer 602 is exposed to the surroundings, and there is no adhesive or other component covering the skin layer 602.

[0055] In some embodiments, the eighth injection molding apparatus 800 is used to implement another injection molding method having several steps shown in FIGS. 67-76. FIG. 67 shows the eighth injection molding apparatus 800 in an open configuration. In some embodiments, the eighth injection molding apparatus 800 includes a first mold 101, a second mold 102, and a feed port 104 similar to those in the first injection molding apparatus 100 or the second injection molding apparatus 200. While FIG. 67 shows only one feed port 104, it should be understood that one or more feed ports 104 may be included. In some embodiments, the eighth injection molding apparatus 800 includes several recesses 110 recessed into the first mold 101 or the second mold 102. While FIG. 67 shows the recesses 110 as being disposed in and recessed into the first mold 101, it should be understood that this is not limiting. In some embodiments, the recesses 110 are configured to temporarily hold material. FIG. 68 is a schematic top cross-sectional view of the eighth injection molding apparatus 800 taken along line GG' in FIG. 67. In some embodiments, the recesses 110 are arranged in a predetermined pattern, for example, the recesses 110 are arranged in a matrix. In some embodiments, the recesses 110 are arranged adjacent to one side (e.g., left side, right side, front side, rear side, etc.) of the eighth injection molding apparatus 800. In some embodiments, the recesses 110 are laterally offset by about 0.8 to 1.6 centimeters from the sidewall of the first mold 101. In some embodiments, the recesses 110 have a height H4 of about 0.3 millimeters and a width W4 of about 0.3 millimeters.

[0056] 69 shows eighth injection molding apparatus 800 in a closed configuration with first mold 101 engaged with second mold 102. In some embodiments, mold cavity 103 is formed when eighth injection molding apparatus 800 is in the closed configuration. In some embodiments, injection apparatus 108 engages eighth injection molding apparatus 800 before or after closing of eighth injection molding apparatus 800. In some embodiments, outlet 108a of injection apparatus 108 engages feed port 104 such that flowable material can flow from injection apparatus 108 through outlet 108a and feed port 104 into mold cavity 103.

[0057] After the injection device 108 is engaged, the flowable material 106′ flows into the mold cavity 103, as shown in FIG. 70 . In some embodiments, the flowable material 106′ fills the recess 110. In some embodiments, the flowable material 106′ is a mixture of a polymeric material (such as polyurethane (PU), thermoplastic polyurethane (TPU)) and a foaming agent (a physical foaming agent, such as carbon dioxide, nitrogen, or a supercritical fluid). The mixture is foamable or micro-foamable. The mixture can undergo a physical foaming process in the mold cavity 103. The mixture in the mold cavity 103 becomes a foamed article after the physical foaming process. In some embodiments, when the flowable material 106′ is injected from the outlet 108a of the injection device 108, the flowable material 106′ flows through the feed port 104 and the mold cavity 103. In some embodiments, during the flow of the flowable material 106', the recesses 110 impede the flow of the polymer and break down any air bubbles under the skin layer (within the product), resulting in an improved contact surface of the product (corresponding to the recesses 110). While in the comparative examples an additional rubbing or grinding step is used to smooth the contact surface, in the injection molding method of the present disclosure, this rubbing or grinding step may not be necessary due to the presence of the recesses 110.

[0058] Figure 71 illustrates opening the eighth injection molding apparatus 800 after the foam article 106 is formed. In some embodiments, the outlet 108a of the injection apparatus 108 engages with the feed port 104 before or after the first mold 101 and second mold 102 disengage. After the first injection molding apparatus 100 is opened, the foam article 106 is removed from the eighth injection molding apparatus 800, as shown in Figures 71 and 72.

[0059] 72 and 73 show foam article 106 formed by eighth injection molding apparatus 800. FIG. 72 is a schematic side view of foam article 106, and FIG. 73 is a schematic perspective view of foam article 106. In some embodiments, foam article 106 includes second protrusion 109 and third protrusion 111. In some embodiments, second protrusion 109 corresponds to and is complementary to at least a portion of feed port 104, and third protrusion 111 corresponds to and is complementary to at least a portion of recess 110.

[0060] In some embodiments, the second protrusion 109 is removed, as shown in FIGS. 74-76. FIG. 74 is a schematic side view of the foam article 106, FIG. 75 is a schematic top view of the foam article 106, and FIG. 76 is a schematic bottom view of the foam article 106. In some embodiments, the second protrusion 109 is removed by cutting, trimming, grinding, or any other suitable process. As a result, a second trimming mark 109' is formed on the top surface of the foam article 106. In some embodiments, the second trimming mark 109' does not include the skin layer because the skin layer is damaged or removed by the trimming process. In some embodiments, the foam article 106 is a component of a footwear article, such as an outsole. The flowable material 106' first flows into and fills the recess 110, and then fills the mold cavity 103, resulting in no or minimal flow marks on the surface of the foam article 106. Furthermore, the flowable material 106' in the eighth injection molding apparatus 800 undergoes uniform foaming, resulting in more evenly distributed voids within the foamed article 106 and a more uniform overall density for the foamed article 106.

[0061] In some embodiments, the ninth injection molding apparatus 900 is used to perform another injection molding method having several steps shown in FIGS. 77-85. FIG. 77 shows the ninth injection molding apparatus 900 in an open configuration. In some embodiments, the ninth injection molding apparatus 900 includes a first mold 101, a second mold 102, and a feed port 104 similar to those in the first injection molding apparatus 100 or the second injection molding apparatus 200. While FIG. 77 shows only one feed port 104, it should be understood that one or more feed ports 104 may be included. In some embodiments, the ninth injection molding apparatus 900 includes a protrusion 112 protruding from the first mold 101 or the second mold 102. While FIG. 77 shows the protrusion 112 disposed in and protruding from the first mold 101, it should be understood that this is not limiting. In some embodiments, the protrusions 112 are configured to temporarily obstruct the flow of material by the horizontal protrusions 112x and the vertical protrusions 112y, temporarily retaining the material within the recesses 113. FIG. 78 is a schematic top cross-sectional view of the ninth injection molding apparatus 900 taken along line HH' in FIG. 77. In some embodiments, the protrusions 112 are formed in a predetermined pattern, for example, the protrusions 112 are formed in a matrix. In some embodiments, the protrusions 112 are positioned adjacent to one side (e.g., left side, right side, front, rear, etc.) of the ninth injection molding apparatus 900. In some embodiments, the protrusions 112 are laterally offset from the sidewall of the first mold 101 by approximately 0.8 to 1.6 centimeters. In some embodiments, the base of the protrusion 112 has a height H5 of approximately 0.3 millimeters, the horizontal protrusion 112x on the base of the protrusion 112 has a height H6 of 0.3 millimeters, and the vertical protrusion 112y on the base of the protrusion 112 has a height H7 of approximately 0.15 millimeters.

[0062] 79 shows the ninth injection molding apparatus 900 in a closed configuration with the first mold 101 engaged with the second mold 102. In some embodiments, the mold cavity 103 is formed when the ninth injection molding apparatus 900 is in the closed configuration. In some embodiments, the injection apparatus 108 engages the ninth injection molding apparatus 900 before or after the ninth injection molding apparatus 900 is closed. In some embodiments, the outlet 108a of the injection apparatus 108 engages the feed port 104 such that flowable material can flow from the injection apparatus 108 through the outlet 108a and the feed port 104 and into the mold cavity 103.

[0063] After the injection device 108 is engaged, the flowable material 106′ flows into the mold cavity 103, as shown in FIG. 80 . In some embodiments, the flowable material 106′ fills the recess 113. In some embodiments, the flowable material 106′ is a mixture of a polymeric material (such as polyurethane (PU), thermoplastic polyurethane (TPU)) and a foaming agent (a physical foaming agent, such as carbon dioxide, nitrogen, or a supercritical fluid). The mixture is foamable or micro-foamable. The mixture can undergo a physical foaming process in the mold cavity 103. The mixture in the mold cavity 103 becomes a foamed article after the physical foaming process. In some embodiments, when the flowable material 106′ is injected from the outlet 108a of the injection device 108, the flowable material 106′ flows through the feed port 104 and the mold cavity 103. In some embodiments, during the flow of flowable material 106', protrusions 112 and recesses 113 impede the flow of the polymer and break down any air bubbles under the skin layer (within the product), resulting in an improved contact surface of the product (corresponding to protrusions 112 and recesses 113). While an additional rubbing or grinding step is used in the comparative examples to smooth the contact surface, this rubbing or grinding step may not be necessary in the injection molding method of the present disclosure due to the presence of protrusions 112 and recesses 113.

[0064] Figure 81 illustrates opening the ninth injection molding apparatus 900 after the foam article 106 is formed. In some embodiments, the outlet 108a of the injection apparatus 108 engages with the feed port 104 before or after the first mold 101 and second mold 102 disengage. After the first injection molding apparatus 100 is opened, the foam article 106 is removed from the ninth injection molding apparatus 900, as shown in Figures 81 and 82.

[0065] 82 and 83 show foam article 106 formed by ninth injection molding apparatus 900. FIG. 82 is a schematic side view of foam article 106, and FIG. 83 is a schematic perspective view of foam article 106. In some embodiments, foam article 106 includes second protrusion 109 and recess 114. In some embodiments, second protrusion 109 corresponds to and is complementary to at least a portion of feed port 104, and recess 114 corresponds to and is complementary to at least a portion of protrusion 112.

[0066] In some embodiments, second protrusion 109 is removed, as shown in FIGS. 84-85 . FIG. 84 is a schematic top view of foam article 106, and FIG. 85 is a schematic bottom view of foam article 106. In some embodiments, second protrusion 109 is removed by cutting, trimming, grinding, or any other suitable process. As a result, second trimming marks 109′ are formed on the top surface of foam article 106. In some embodiments, second trimming marks 109′ do not include the skin layer because the skin layer is damaged or removed by the trimming process. In some embodiments, foam article 106 is a component of a footwear article, such as an outsole. Flowable material 106′ first flows into and fills recess 113 to form recess 114, and then fills mold cavity 103, resulting in minimal or no flow marks on the surface of foam article 106. Furthermore, the flowable material 106' in the ninth injection molding apparatus 900 undergoes uniform foaming, resulting in more evenly distributed voids within the foamed article 106 and a more uniform overall density for the foamed article 106.

Claims

1. providing a molding apparatus including a first mold and a second mold, the first mold including a recess recessed therein, and the second mold including a supply port extending through the second mold; Engaging the first mold and the second mold to form a mold cavity defined by the first mold and the second mold and capable of communicating with the recess and the supply port; injecting a flowable material through the feed port into the mold cavity to fill the recess and the mold cavity; and foaming the flowable material to obtain a foamed article.

2. The method of claim 1 , wherein the supply port is aligned with the recess.

3. the foam article includes a first protrusion within the recess; The molding method includes: removing the foamed article from the molding apparatus; removing the first protrusion from the foam article; The method of claim 1 , wherein after removal, the foam article has a first trimming mark corresponding to the first protrusion.

4. the foam article includes a second protrusion within the feed opening; The molding method includes: further comprising removing the second protrusion from the foam article; After removal, a second trimming mark is formed on the foam article corresponding to the second protruding portion, The method of claim 3 , wherein the first protrusions are aligned with the second protrusions.

5. providing a molding apparatus including a first mold and a second mold, wherein the first mold or the second mold includes a cooling mechanism embedded in the first mold, and the second mold includes a supply port extending through the second mold; mating the first mold and the second mold to form a mold cavity defined by the first mold and the second mold; injecting a flowable material through the feed port into the mold cavity; activating the cooling mechanism to cool the flowable material surrounding the cooling mechanism; and foaming the flowable material to obtain a foamed article.

6. 6. The method of claim 5, wherein the foam article has a skin layer adjacent the cooling feature, the skin layer having a density gradient that gradually increases from the interior of the foam article to the exterior of the foam article.

7. adjusting the molding apparatus to a first predetermined temperature prior to injecting the flowable material; maintaining the molding apparatus at the first predetermined temperature during injection of the flowable material; 6. The method of claim 5, wherein operating the cooling mechanism comprises cooling the flowable material surrounding the cooling mechanism from the first predetermined temperature to a second predetermined temperature that is substantially lower than the first predetermined temperature.

8. 7. The method of claim 6, wherein the first mold includes a recess recessed into the first mold and coupled to the mold cavity, the flowable material flows into the recess during injection of the flowable material into the mold cavity, and the foamed article includes a first protrusion within the recess, and the density of the skin layer is substantially greater than the density of the first protrusion.

9. a first surface, a second surface opposite the first surface, and a third surface between the first surface and the second surface; a first trace disposed on the first surface; a second trace disposed on the second surface, opposite the first trace and perpendicularly aligned with the first trace.

10. further comprising a skin layer exposed from the first surface, the second surface, or the third surface; 10. The foam article of claim 9, wherein the skin layer has a higher abrasion resistance than the remainder of the foam article, and the skin layer has a density gradient that gradually increases from the interior of the foam article to the exterior of the foam article.

Images