Method for cleaning injection molding systems and fluid supply units

Abstract

This invention relates to a cleaning mechanism for a fluid supply unit of an injection molding system and an injection molding method for performing a cleaning procedure in a fluid supply unit. [Solution] The mixing unit is configured to mix a fluid polymer material with a foaming agent to form a mixture. The fluid supply unit is configured to supply the foaming agent to the mixing unit. The fluid supply unit includes an injection port coupled to the mixing unit, a compressor configured to produce the foaming agent, an injection valve positioned between the injection port and the compressor and configured to receive the foaming agent from the compressor through a first passage, and a cleaning mechanism configured to clean the injection valve. The cleaning mechanism includes a control valve coupled to the compressor through a second passage and coupled to the injection valve through a third passage connected to the first passage, and an actuator configured to actuate the control valve. The foaming agent is flowable to the injection valve through the control valve.

Description

Technical Field

[0001] (Cross - reference to related applications) This application claims priority to U.S. Provisional Patent Application No. 63 / 689,862, filed on September 3, 2024, and U.S. Patent Application No. 19 / 208,537, filed on May 14, 2025, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to an injection molding system and an injection molding method, and particularly to a cleaning mechanism of a fluid supply unit of an injection molding system and an injection molding method for performing a cleaning procedure in the fluid supply unit.

Background Art

[0003] Foamed polymer materials have many advantages such as high strength, light weight, impact resistance, and heat insulation. Foamed articles can be produced by injection molding or extrusion molding. For example, in an injection molding system, a polymer material is melted and mixed with a foaming agent to form a mixture, and then force or pressure is applied to the mixture to inject or extrude the mixture into the cavity of a mold, and the mixture is foamed in the cavity and cooled to form a foamed article.

[0004] However, during the formation of an article, residues may accumulate in the injection molding system. The presence of these residues can have an adverse effect on product quality, lead to the occurrence of defects, and increase the need for maintenance and downtime. Therefore, it is necessary to improve the injection molding system and its operation method to facilitate the cleaning of residues.

Summary of the Invention

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

[0006] According to one embodiment of the present disclosure, an injection molding system is provided. The injection molding system includes a mixing unit and a fluid supply unit. The mixing unit is configured to mix a fluid polymer material with a foaming agent to form a mixture. The fluid supply unit is configured to supply the foaming agent to the mixing unit. The fluid supply unit includes an injection port coupled to the mixing unit, a compressor configured to produce the foaming agent, an injection valve positioned between the injection port and the compressor and configured to receive the foaming agent from the compressor through a first passage, and a cleaning mechanism configured to clean the injection valve. The cleaning mechanism includes a control valve coupled to the compressor through a second passage and coupled to the injection valve through a third passage connected to the first passage, and an actuator configured to actuate the control valve. The foaming agent is flowable to the injection valve through the second passage, the third passage, and the control valve.

[0007] An injection molding method is provided according to one embodiment of the present disclosure. The injection molding method includes the steps of supplying a foaming agent from a compressor of a fluid supply unit to a mixing unit via a first passage of the fluid supply unit and an injection valve of the fluid supply unit; mixing a fluid polymer material with the foaming agent to form a mixture in a mixing unit coupled to the fluid supply unit; and cleaning the injection valve with a cleaning mechanism of the fluid supply unit during or after the formation of the mixture. The step of cleaning the injection valve with the cleaning mechanism further includes the steps of activating a control valve of the cleaning mechanism, which is connected to the compressor by a second passage and to the first passage by a third passage; and supplying a foaming agent from the compressor to the injection valve via the second passage, the control valve and the third passage. [Brief explanation of the drawing]

[0008] The aspects of this disclosure will be best understood from the following detailed description when read in conjunction with the accompanying drawings. Note that, in accordance with standard practice in this industry, various features are not drawn to scale. In fact, the dimensions of various features may be arbitrarily enlarged or reduced for illustrative purposes.

[0009] [Figure 1] This invention relates to an injection molding system according to several embodiments of the present disclosure.

[0010] [Figure 2] This invention relates to an injection molding system according to several embodiments of the present disclosure.

[0011] [Figure 3] This is a fluid supply unit for an injection molding system shown in Figures 1 and 2, according to some embodiments of the present disclosure.

[0012] [Figure 4] A method 400 for operating an injection molding system according to some embodiments of the present disclosure.

[0013] [Figure 5] This invention provides a method for performing a cleaning procedure to clean the injection valve shown in Figure 3, according to some embodiments of the present disclosure. [Modes for carrying out the invention]

[0014] The following disclosure provides many different embodiments or examples for implementing different features of the subject matter provided. For the sake of brevity, specific examples of components and configurations are described below. Naturally, these are merely examples and not intended to be limiting. For example, in the following description, forming a first feature over or on a second feature may include embodiments in which the first and second features are formed in direct contact, or it may include embodiments in which an additional feature can be formed between the first and second features so that they do not come into direct contact. Furthermore, in various examples in this disclosure, reference numbers and / or letters may be repeated. This repetition is for the purpose of simplification and clarity and does not in itself indicate relationships between the various embodiments and / or configurations discussed.

[0015] Furthermore, spatially relative terms such as “downward,” “below,” “bottom,” “upward,” and “top” may also be used herein to describe the relationship between one element or feature and another, as shown in the drawings for the sake of clarity. Spatially relative terms are intended to encompass different orientations of the device in use or operation, in addition to the orientation depicted in the drawings. The device may be oriented in a different direction (it may be rotated 90° or in other directions), and the spatially relative descriptors used herein may be interpreted accordingly.

[0016] Although the numerical ranges and parameters representing the broad scope of this disclosure are approximations, the numerical values ​​described in the specific examples are reported as accurately as possible. However, every numerical value inherently contains a certain degree of error that inevitably arises from the standard deviation observed in each test measurement. Furthermore, as used herein, the term “about” generally means within 10%, 5%, 1%, or 0.5% of a given value or range. Alternatively, the term “about” means within the acceptable standard error of the mean, as considered by those skilled in the art. Except in the operations / examples, or unless otherwise explicitly stated, all numerical ranges, quantities, values, and percentages disclosed herein, such as quantities of material, durations of time, temperatures, operating conditions, and ratios of quantities, should be understood in all cases to be modified by the term “about.” Therefore, unless otherwise indicated, the numerical parameters described in this disclosure and the appended claims are approximations that may vary as desired. At a minimum, each numerical parameter should be interpreted by applying common rounding techniques in light of the number of significant figures reported. Ranges may be expressed herein as from one endpoint to another, or between two endpoints. All ranges disclosed herein include endpoints unless otherwise specified.

[0017] Figure 1 shows an injection molding system 100A according to several embodiments of the present disclosure. The injection molding system 100A includes a melting unit 101, a fluid supply unit 102, a mixing unit 103, and an injection unit 104. The melting unit 101 is coupled to the mixing unit 103 via at least one delivery channel 151. In some embodiments, the melting unit 101 is configured to receive raw polymer material, heat and melt the raw polymer material to make it a fluid polymer material (i.e., in a molten state), and extrude the fluid polymer material. The fluid polymer material is then delivered to the mixing unit 103 via the delivery channel 151. In some embodiments, the fluid polymer material includes ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), and the like.

[0018] The fluid supply unit 102 is coupled to the mixing unit 103 via at least one delivery channel 152. In some embodiments, the fluid supply unit 102 is configured to supply fluid to the mixing unit 103. In some embodiments, the fluid supply unit 102 is configured to convert an inert gas (e.g., carbon dioxide or nitrogen) to a supercritical state and supply the supercritical fluid to the mixing unit 103. In some embodiments, the fluid supplied by the fluid supply unit 102 is a chemical or physical blowing agent. The blowing agent is then delivered to the mixing unit 103 via the delivery channel 152.

[0019] The mixing unit 103 is configured to mix the fluid polymer material from the melting unit 101 with a fluid (e.g., a supercritical foaming agent) from the fluid supply unit 102 to form a mixture. In some embodiments, the mixing unit 103 includes a mixing chamber and a mixing screw inside the mixing chamber. The fluid polymer material and the fluid are delivered to the mixing chamber, where they are mixed by the mixing screw to form a mixture within the chamber. In some embodiments, the mixing screw is configured to rotate to mix (or blend) the fluid polymer material and the fluid to form a mixture.

[0020] The mixing unit 103 is coupled to the injection unit 104 via at least one delivery channel 153. In some embodiments, the mixing screw of the mixing unit 103 is configured to rotate to deliver the mixture to the injection unit 104 via the delivery channel 153. The injection unit 104 is configured to receive the mixture from the mixing unit 103 and discharge the mixture from the injection unit 104. In some embodiments, the injection unit 104 includes at least one injector for injecting the mixture from the injection unit 104.

[0021] Figure 2 shows an injection molding system 100B according to some embodiments of the present disclosure. Compared to the injection molding system 100A of Figure 1, the injection molding system 100B further includes a molding apparatus 105. An injection unit 104 is able to communicate with the molding apparatus 105 via at least one injector 154. In some embodiments, the molding apparatus 105 is configured to receive a mixture from the injection unit 104 and to form an article from the mixture inside the molding apparatus 105. In some embodiments, the molding apparatus 105 includes at least one supply port (not shown) for the mixture to flow through and a mold cavity (not shown) for receiving and holding the mixture. In some embodiments, the mixture is injected into the mold cavity via the supply port by the injection unit 104. In some embodiments, after the mixture has been injected into the mold cavity, the mixture undergoes a physical foaming process within the mold cavity to become a foamed article.

[0022] Figure 3 shows a fluid supply unit 102 of the injection molding system of Figures 1 and 2 according to some embodiments of the present disclosure. In some embodiments, the fluid supply unit 102 includes a first gas source 106, a compressor 108, an injection valve 110, and an injection outlet 109. In some embodiments, the first gas source 106 is connected to the compressor 108 and configured to supply gas G1 to the compressor 108. In some embodiments, gas G1 may include nitrogen, carbon dioxide, etc. In some embodiments, the compressor 108 is configured to receive gas G1 (e.g., nitrogen, carbon dioxide, etc.) from the first gas source 106 and then compress or pressurize gas G1 to become a specific gas. In some embodiments, the specific gas is a supercritical physical foaming agent for a subsequent physical foaming process.

[0023] In some embodiments, the physical blowing agent is discharged from the compressor 108 through the first passage 118 towards the injection valve 110. In some embodiments, the physical blowing agent discharged from the compressor 108 flows through the injection valve 110 to the injection outlet 109. As shown in FIGS. 1 and 2, the injection outlet 109 can communicate with the mixing unit 103 through the delivery channel 152. The physical blowing agent is supplied from the compressor 108 to the mixing unit 103 through the injection valve 110, the injection outlet 109, and the delivery channel 152. In some embodiments, the injection valve 110 is configured to control the passage of the physical blowing agent. When the injection valve 110 is turned on, the physical blowing agent can pass through the injection valve 110 and flow into the mixing unit 103. When the injection valve 110 is turned off, the physical blowing agent is blocked by the injection valve 110 and cannot flow into the mixing unit 103. In some embodiments, the injection valve 110 is a gate valve, a plug valve, a ball valve, or the like.

[0024] In some embodiments, the metering unit 115 is disposed in the first passage 118 between the compressor 108 and the injection valve 110. The metering unit 115 is configured to measure the flow rate of the physical blowing agent passing through the mixing unit 103 and / or the amount of the physical blowing agent entering the mixing unit 103 within a certain period. In some embodiments, the first check valve 117 is disposed in the first passage 118 and between the metering unit 115 and the injection valve 110. The first check valve 117 is configured to prevent the physical blowing agent or any other fluid from flowing backward from the mixing unit 103 towards the compressor 108 or from the injection valve 110 towards the metering unit 115.

[0025] In some embodiments, the first passage 118 is divided into sub-passages 118a, 118b, and 118c. The metering unit 115 is connected to the compressor 108 via the sub-passage 118a and is connected to the first check valve 117 via the sub-passage 118b. The first check valve 117 is connected to the injection valve 110 via the sub-passage 118c. In some embodiments, the sub-passage 118a is implemented by a high-pressure pipe and has explosion-proof performance. In some embodiments, the sub-passages 118b and 118c are implemented by seamless steel pipes.

[0026] After the physical blowing agent is supplied to the mixing unit 103, the physical blowing agent is mixed in the mixing unit 103 with the fluid polymeric material provided by the melting unit 101 so as to form a mixture containing both the physical blowing agent and the fluid polymeric material. After forming the mixture in the mixing unit 103, the mixture is injected into the mold cavity of the molding device 105 by the injection unit 104. Then, the mixture undergoes a physical foaming process in the mold cavity and becomes a foamed article.

[0027] During operation of the injection molding system 100, some undesirable materials (e.g., residues, dirt, etc.) accumulate on or around the injection valve 110. These undesirable materials adhere to the injection valve 110 and may thus have an adverse effect on the performance or operation of the injection valve 110. Therefore, it is necessary to clean the injection valve 110 (e.g., by removing these undesirable materials). In other words, a cleaning procedure for the injection valve 110 is required to avoid a decrease in the performance of the injection molding systems 100A and 100B. In some embodiments, the monitoring device 250 is arranged adjacent to the injection valve 110 and is configured to monitor the accumulation of undesirable materials. In some embodiments, the sensor 260 is arranged adjacent to the injection valve 110 and is configured to detect the presence of undesirable materials.

[0028] In Figure 3, the fluid supply unit 102 further includes a cleaning mechanism 200 for cleaning the injection valve 110. In some embodiments, the cleaning mechanism 200 is coupled adjacent to the injection valve 110. In some embodiments, the cleaning mechanism 200 is connected to the injection valve 110 via a third passage 113. In some embodiments, the cleaning mechanism 200 is configured to perform a cleaning procedure for cleaning the injection valve 110 when a monitoring device 250 or sensor 260 determines that cleaning is necessary. By implementing the cleaning mechanism 200 in the fluid supply unit 102, the injection valve 110 can be easily cleaned without removing the injection valve 110 and the passages around it. This prevents fluid leakage from the fluid supply unit 102 or the injection molding system 100.

[0029] In some embodiments, the cleaning mechanism 200 includes an actuator 112 and a control valve 111 connected to the actuator 112. The actuator 112 is configured to receive a signal Ctrl and output force according to a control signal Ctrl in order to actuate the control valve 111. In some embodiments, the signal Ctrl is input manually, for example, by an operator pressing a button or by an operator touching the screen of a computer connected to the actuator 112. In some embodiments, the actuator 112 is operated automatically so that force is output automatically. In some embodiments, the actuator 112 is under automatic control by a computing program such as a programmable logic controller (PLC). In some embodiments, the signal Ctrl is input remotely and / or wirelessly.

[0030] In some embodiments, the actuator 112 is operated automatically at predetermined intervals. For example, the actuator 112 is operated automatically every 10 minutes. In some embodiments, the actuator 112 is a hydraulic cylinder, a pneumatic cylinder, a motor, etc. In some embodiments, a second gas source 107 is connected to the actuator 112. In some embodiments, the second gas source 107 is configured to supply a second gas G2 (e.g., air) to the actuator 112. In some embodiments, the second gas G2 is a compressed or pressurized gas for operating the actuator 112. In some embodiments, the second gas G2 is supplied to the actuator 112 when it receives a signal Ctrl manually or automatically. In some embodiments, the first gas G1 is different from the second gas G2. For example, the first gas G1 is nitrogen and the second gas G2 is air.

[0031] In some embodiments, this force is output from the actuator 112 when the actuator 112 receives a second gas G2. In some embodiments, this force is provided to actuate the control valve 111, such as turning the control valve 111 on or off. In some embodiments, the control valve 111 is rotated by the actuator 112 at a predetermined angle to be turned on or off. In some embodiments, the control valve 111 is configured to control the fluid flowing through it. In some embodiments, the fluid is allowed to flow when the control valve 111 is turned on and is blocked from flowing when the control valve 111 is turned off. In some embodiments, the control valve 111 is automatically turned on by the actuator 112 at predetermined intervals. For example, the control valve 111 is automatically turned on by the actuator 112 every 10 minutes. In some embodiments, the control valve 111 is automatically turned on by the actuator 112 for a predetermined duration. For example, the control valve 111 is turned on for 10 seconds and then turned off. In some embodiments, the control valve 111 is a gate valve, a plug valve, a ball valve, etc.

[0032] In some embodiments, the physical foaming agent can flow from the compressor 108 towards the injection valve 110 via a second passage 119 and along a third passage 113 through a control valve 111 during the cleaning procedure. In some embodiments, the physical foaming agent is allowed to flow from the compressor 108 towards the injection valve 110 via a second passage 119 and along a third passage 113 when the control valve 111 is turned on.

[0033] If cleaning of the injection valve 110 is required, after performing the cleaning procedure, the control valve 111 is turned on so that the physical foaming agent is blown out through the control valve 111 towards the injection valve 110, and the injection valve 110 is cleaned by the physical foaming agent from the turned-on control valve 111. Any undesirable material on or around the injection valve 110 may be blown away by the physical foaming agent during the cleaning procedure.

[0034] In some embodiments, the injection valve 110 is turned off during the cleaning procedure, and the physical foaming agent cannot flow from the compressor 108 along the first passage 118 through the metering unit 115 toward the injection valve 110. In some embodiments, the injection valve 110 is turned on during the cleaning procedure, and the physical foaming agent can flow from the compressor 108 along the first passage 118 through the metering unit 115 toward the injection valve 110. In some embodiments, the physical foaming agent can flow through the control valve 111 to clean the injection valve 110 for a predetermined duration. For example, the physical foaming agent is flowed through the control valve 111 to clean the injection valve 110 for 10 seconds.

[0035] In some embodiments, a second check valve 116 is located in a third passage 113, between the control valve 111 and the injection valve 110. The second check valve 116 is configured to prevent backflow of the physical foaming agent or any other fluid from the injection valve 110 toward the control valve 111, or from the injection valve 110 toward the compressor 108. In some embodiments, when the injection valve 110 is turned on, allowing the physical foaming agent to flow into the mixing unit 103 through the turned-on injection valve 110, the second check valve 116 is configured to prevent the physical foaming agent from flowing toward the control valve 111. In some embodiments, a first check valve 117 is configured to prevent the physical foaming agent from flowing through or toward the metering unit 115 during a cleaning procedure, during which the control valve 111 is turned on, and the physical foaming agent is allowed to flow toward the injection valve 110 and clean it.

[0036] In some embodiments, the third passage 113 is divided into sub-passages 113a and 113b by a second check valve 116. The second check valve 116 is connected to a control valve 111 via sub-passage 113a and to a first check valve 117 via sub-passage 113b. The first check valve 117 is connected to the first passage 118 via sub-passage 118b. In some embodiments, the sub-passages 113a and 113b are implemented by seamless steel pipes.

[0037] After the cleaning procedure of the injection valve 110, the physical foaming agent is prevented from flowing from the compressor 108 through the control valve 111 towards the injection valve 110. In some embodiments, a force is output from the actuator 112 to turn off the control valve 111, preventing the physical foaming agent from the compressor 108 from flowing through the third passage 113.

[0038] Figure 4 shows a method 400 for operating an injection molding system according to some embodiments of the present disclosure (for example, injection molding system 100A in Figure 1 and injection molding system 100B in Figure 2).

[0039] In operation S410, the physical blowing agent from the fluid supply unit 102 is supplied to the mixing unit 103. Simultaneously, the fluid polymer material from the melting unit 101 is also supplied to the mixing unit 103. In some embodiments, the physical blowing agent is discharged from the fluid supply unit 102 to the mixing unit 103 via an injection outlet 109. In some embodiments, the physical blowing agent is discharged from the compressor 108 to the mixing unit 103 via a first passage 118, an injection valve 110, and an injection outlet 109. In some embodiments, a metering unit 115 is located in the first passage 118 and is configured to measure the flow rate of the physical blowing agent passing through and / or the amount of physical blowing agent entering the mixing unit 103 over a period of time.

[0040] In operation S420, the physical blowing agent from the fluid supply unit 102 and the fluid polymer material from the melting unit 101 are mixed in the mixing unit 103 to form a mixture within the mixing unit 103. In operation S430, a cleaning procedure is performed in which the injection valve is cleaned by the cleaning mechanism 200 during or after the formation of the mixture. In some embodiments, the cleaning procedure is performed when monitoring that the amount of undesirable material accumulated on or around the injection valve 110 exceeds a threshold, or when it is detected that undesirable material is present inside the injection valve 110.

[0041] In some embodiments, the method 400 for operating the injection molding system further includes injecting a mixture from a mixing unit 103 into a molding apparatus 105 by an injection unit 104. In some embodiments, the mixture is injected into the mold cavity of the molding apparatus 105 by the injection unit 104. In some embodiments, the method 400 for operating the injection molding system further includes foaming the mixture inside the molding apparatus 105 to form a foamed article. The mixture undergoes a physical foaming process in the mold cavity to form a foamed article. After the physical foaming process, the foamed article is removed from the mold cavity.

[0042] Figure 5 shows a method 500 for performing a cleaning procedure to clean the injection valve 110 of Figure 3, according to some embodiments of the present disclosure. In some embodiments, the method 500 for performing a cleaning procedure to clean the injection valve 110 is performed during or after the formation of the mixture. In some embodiments, the method 500 is performed by the cleaning mechanism 200 of Figure 3 of an injection molding system (e.g., injection molding system 100A of Figure 1 or injection molding system 100B of Figure 2).

[0043] In operation S510, the control valve 111 is actuated (or turned on) by the actuator 112. In some embodiments, the control valve 111 is connected to the compressor 108 via a second passage 119, and the control valve 111 is connected to the first passage 118 via a third passage 113. In some embodiments, the control valve 111 is actuated by the actuator 112 when the signal Ctrl is received by the actuator 112.

[0044] In operation S520, a physical blowing agent is supplied from the compressor 108 to the injection valve 110 via the second passage 119, the control valve 111, and the third passage 113 to clean the injection valve 110 by removing any undesirable material inside it. In some embodiments, the actuator 112 is configured to actuate and turn on the control valve 111, so that the physical blowing agent can flow from the compressor 108 through the control valve 111 towards the injection valve 110, blowing and cleaning the injection valve 110.

[0045] In operation S530, once the cleaning procedure is complete, the control valve 111 is deactivated. In some embodiments, the control valve 111 is turned off by the actuator 112 when the cleaning of the injection valve 110 is complete. In some embodiments, the control valve 111 is automatically turned off by the actuator 112 after a predetermined duration. In some embodiments, the control valve 111 is turned off manually by the actuator 112, and the signal Ctrl is input to the actuator 112 by the operator to turn off the control valve 111.

[0046] In some embodiments, the injection valve 110 is turned off during the cleaning procedure so that the physical foaming agent does not flow through the injection valve 110 and the metering unit 115. In some embodiments, the injection valve 110 is turned on during the cleaning procedure so that the physical foaming agent flows through the injection valve 110 and the metering unit 115. In some embodiments, the cleaning procedure is performed after the physical foaming agent has been supplied to the mixing unit 103.

[0047] In some embodiments, the cleaning of the injection valve 110 continues for a predetermined period (e.g., a few seconds, a few minutes) during the cleaning procedure. In some embodiments, the injection valve 110 is turned off during the cleaning procedure so that the physical foaming agent cannot flow from the first passage 118 through the metering unit 115 and the injection valve 110 to the mixing unit 103. In some embodiments, the injection valve 110 is turned on during the cleaning procedure so that the physical foaming agent can flow from the first passage 118 through the metering unit 115 and the injection valve 110 to the mixing unit 103.

[0048] In some embodiments, after cleaning the injection valve 110, the supply of physical blowing agent into the mixing unit 103 is resumed from the compressor 108 through the first passage 118 and the metering unit 115 toward the injection valve 110 and the injection outlet 109. The physical blowing agent can be discharged from the compressor 108 through the first passage 118 and flow into the mixing unit 103 through the injection valve 110 and the injection outlet 109.

[0049] According to this embodiment, by using a cleaning mechanism 200 in the fluid supply unit 102, the injection valve 110 can be easily cleaned without removing the injection valve 110 and the flow path around the injection valve 110. As a result, fluid leakage from the fluid supply unit 102 or the injection molding system 100 can be prevented.

[0050] The above outlines features of several embodiments so that those skilled in the art may better understand aspects of the disclosure. Those skilled in the art should understand that aspects of the disclosure may be readily used as a basis for designing or modifying other processes and structures to accomplish the same objectives and / or achieve the same advantages as the embodiments described herein. Those skilled in the art should also recognize that such equivalent configurations will not deviate from the spirit and scope of the disclosure, and that various changes, substitutions, and modifications may be made herein without deviating from the spirit and scope of the disclosure.

[0051] Furthermore, the scope of this application is not intended to be limited to specific embodiments of the processes, machines, manufactures, compositions, means, methods, and steps described herein. As will be readily apparent to those skilled in the art from the disclosure, existing or subsequently developed processes, machines, manufactures, compositions, means, methods, or steps that perform substantially the same functions or achieve substantially the same results as the corresponding embodiments described herein can be utilized in accordance with this disclosure. Accordingly, the appended claims are intended to include such processes, machines, manufactures, compositions, means, methods, and steps within their scope.

Claims

1. An injection molding system, A mixing unit configured to mix a fluid polymer material with a foaming agent to form a mixture, A fluid supply unit configured to supply the foaming agent to the mixing unit, The fluid supply unit is equipped with, An injection outlet connected to the mixing unit, A compressor configured to generate the aforementioned foaming agent, An injection valve is positioned between the injection outlet and the compressor and configured to receive the foaming agent from the compressor via a first passage, A cleaning mechanism configured to clean the injection valve, A control valve coupled to the compressor via a second passage and coupled to the injection valve via a third passage connected to the first passage, A cleaning mechanism comprising an actuator configured to operate the control valve, Equipped with, An injection molding system in which the foaming agent is flowable to the injection valve via the second passage, the third passage, and the control valve.

2. The aforementioned fluid supply unit is A metering unit is positioned between the compressor and the injection valve and configured to measure the flow rate of the foaming agent passing through the first passage, A first check valve is positioned within the first passage between the compressor and the injection valve and configured to prevent the foaming agent from flowing from the injection valve toward the compressor, The injection molding system according to claim 1, further comprising the above.

3. The cleaning mechanism is A second check valve is positioned between the control valve and the injection valve within the third passage and configured to prevent the foaming agent from flowing from the injection valve toward the control valve. The injection molding system according to claim 1, further comprising the above.

4. A first gas source connected to the compressor and configured to supply the first gas to the compressor in order to generate the blowing agent. The injection molding system according to claim 1, further comprising the above.

5. The cleaning mechanism is A second gas source connected to the actuator and configured to supply a second gas to the actuator in order to actuate the control valve. The injection molding system according to claim 1, further comprising the above.

6. The cleaning mechanism is A monitoring device positioned adjacent to the injection valve and configured to monitor the accumulation of undesirable material on or around the injection valve, or A sensor positioned adjacent to the injection valve and configured to detect the presence of the undesirable material. The injection molding system according to claim 1, further comprising the above.

7. An injection molding method, A step of supplying a foaming agent from the compressor of the fluid supply unit to the mixing unit via the injection valve of the fluid supply unit through the first passage of the fluid supply unit, The steps include: mixing a fluid polymer material with the foaming agent to form a mixture in the mixing unit connected to the fluid supply unit; The steps include cleaning the injection valve with the cleaning mechanism of the fluid supply unit during or after the formation of the mixture, Includes, The step of cleaning the injection valve with the cleaning mechanism is: A step of operating the control valve of the cleaning mechanism, which is connected to the compressor by a second passage and to the first passage by a third passage, The steps include supplying the foaming agent from the compressor to the injection valve via the second passage, the control valve, and the third passage, An injection molding method further comprising the above.

8. The step of cleaning the injection valve with the cleaning mechanism of the fluid supply unit during or after the formation of the mixture is: The step of deactivating the control valve when the cleaning of the injection valve is complete, thereby preventing the foaming agent from flowing from the compressor along the control valve toward the injection valve. The injection molding method according to claim 7, further comprising:

9. The steps include: measuring the flow rate of the foaming agent passing through the first passage using the metering unit of the fluid supply unit; During the cleaning of the injection valve, a first check valve positioned between the metering unit and the injection valve is used to block the flow of the foaming agent from the injection valve toward the metering unit. The steps include: when the foaming agent is discharged from the compressor to the mixing unit via the first passage, a second check valve positioned between the control valve and the injection valve blocks the flow of the foaming agent from the injection valve toward the control valve; The injection molding method according to claim 7, further comprising:

10. The step of cleaning the injection valve with the cleaning mechanism is: A step of monitoring the accumulation of undesirable material on or around the injection valve, or a step of sensing the presence of the undesirable material, When the accumulation of the undesirable material exceeds a threshold, or when the undesirable material is present, the cleaning mechanism cleans the injection valve. The injection molding method according to claim 7, further comprising:

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