Injection molding system and injection molding method

Abstract

To provide an injection molding system and injection molding method.SOLUTION: There is provided an injection molding system and method. The injection molding system includes a molding device and an injector. The molding device defines a mold cavity and includes an inlet portion in communication with the mold cavity. The injector includes a discharging channel. An end portion of the inlet portion and an end portion of the discharging channel have non-planar end surfaces respectively, and both thereof are engageable with each other.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Non-Provisional Patent Application No. 17 / 812,722, filed July 15, 2022, which is incorporated by reference herein as if fully set forth.

[0002] The present invention relates to an injection molding system and an injection molding method, and more particularly to an injection molding system and an injection molding method for producing polymer molded articles. [Background technology]

[0003] Polymeric materials have many advantages, such as high strength, lightness, impact resistance, thermal insulation, etc. Polymeric molded articles can be manufactured by injection molding or extrusion molding. For example, the polymeric material can be melted and mixed with a blowing agent to form a mixture, and then the mixture can be injected or extruded into a mold cavity, where it can foam and cool to form a molded article.

[0004] Generally, the appearance and physical properties of polymer molded products are directly affected by the molding process, so the design of the mold must take into account the flowability of the mixture so that the mixture can be distributed uniformly and quickly in the cavity. Polymer molded products molded using molds have many advantages and applications, but the limitations and restrictions caused by their disadvantages have not yet been resolved. Summary of the Invention [Problem to be solved by the invention]

[0005] SUMMARY OF THE PRESENT EMBODIMENT It is an object of the present invention to provide an injection molding system and method. [Means for solving the problem]

[0006] According to one embodiment of the present invention, an injection molding system is disclosed. The injection molding system includes a molding apparatus and an injection apparatus. The molding apparatus includes an inlet portion defining a mold cavity and communicating with the mold cavity. The injection apparatus includes a discharge channel. An end of the inlet portion and an end of the discharge channel each have a non-planar end surface and are mutually engageable.

[0007] According to one embodiment of the present invention, an injection molding system is disclosed. The injection molding system includes a molding device, an injection device, and a self-alignment mechanism. The molding device defines a mold cavity and a first passageway in communication with the mold cavity. The injection device defines a receiving space and a second passageway in communication with the receiving space. The self-alignment mechanism is used to align an opening of the first passageway of the molding device with an opening of the second passageway of the injection device.

[0008] According to one embodiment of the present invention, a method of injection molding is disclosed, comprising the steps of: providing a molding apparatus including an inlet portion defining a mold cavity and communicating with the mold cavity, providing an injection apparatus including a discharge channel, and engaging an end of the inlet portion with an end of the discharge channel such that an opening of a second passageway defined by the discharge channel self-aligns with an opening of a first passageway defined by the inlet portion.

[0009] Aspects of the present invention will become better understood from the accompanying drawings and the following detailed description. It should be noted that, according to standard practice in the industry, various features are not drawn to scale. In fact, dimensions of various features may be arbitrarily increased or decreased for clarity of illustration. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a schematic top view of an injection molding system according to one embodiment of the present invention. [Diagram 2] 2 is a schematic cross-sectional view of the injection device taken along line II in FIG. 1. [Diagram 3]2 is a schematic cross-sectional view of the molding apparatus taken along line II-II in FIG. 1. [Figure 4] FIG. 2 is a schematic top view of the injection molding system of FIG. 1, showing the injection device moving horizontally to a position corresponding to the molding device. [Diagram 5] 5 is a schematic cross-sectional view of the injection device and the molding device taken along line III-III in FIG. 4. [Figure 5A] FIG. 2 is a schematic cross-sectional view of an injection molding system showing the injection device moving horizontally to a position corresponding to the molding device. [Figure 6] FIG. 2 is a schematic cross-sectional view of the injection molding system showing the injection device moving downward and contacting the molding device. [Figure 6A] 1 is a schematic cross-sectional view of an injection molding system according to one embodiment of the present invention. [Figure 7] FIG. 1 is a schematic top view of an injection molding system according to one embodiment of the present invention. [Figure 8] 8 is a schematic cross-sectional view of the injection device taken along line IV-IV in FIG. 7. [Figure 9] 8 is a schematic cross-sectional view of the molding apparatus taken along line VV in FIG. 7. [Figure 10] FIG. 8 is a schematic top view of the injection molding system of FIG. 7, showing the injection device moving horizontally to a position corresponding to the molding device. [Figure 11] 11 is a schematic cross-sectional view of the injection device and the molding device taken along line VI-VI in FIG. 10. [Figure 12] FIG. 11 is a schematic cross-sectional view of the injection molding system of FIG. 10 showing the injection device moving downward and contacting the molding device. [Figure 13] 1 is a schematic cross-sectional view of an injection molding system according to one embodiment of the present invention. [Figure 14] FIG. 14 is a schematic cross-sectional view of the injection molding system of FIG. 13 showing the injection tool moving downward and contacting the molding tool. [Figure 15] 1 is a schematic cross-sectional view of an injection molding system according to one embodiment of the present invention. [Figure 16]FIG. 16 is a schematic cross-sectional view of the injection molding system of FIG. 15 showing the injection tool moving downward and contacting the molding tool. [Figure 17] 1 is a schematic cross-sectional view of an injection molding system according to one embodiment of the present invention. [Figure 18] FIG. 18 is a schematic cross-sectional view of the injection molding system of FIG. 17 showing the injection device moving downward and contacting the molding device. [Figure 19] 1 is a schematic cross-sectional view of an injection molding system according to one embodiment of the present invention. [Figure 20] FIG. 20 is a schematic cross-sectional view of the injection molding system of FIG. 19 showing the injection device moving downward and contacting the molding device. [Figure 21] 1 is a schematic cross-sectional view of an injection molding system according to one embodiment of the present invention. [Figure 22] FIG. 22 is a schematic cross-sectional view of the injection molding system of FIG. 21 showing the injection device moving downward and contacting the molding device. [Diagram 23] FIG. 1 is a schematic top view of an injection molding system according to one embodiment of the present invention. [Figure 24] 24 is a schematic cross-sectional view of the molding apparatus taken along line VII-VII in FIG. 23. [Diagram 25] FIG. 25 is a schematic cross-sectional view showing the flow of the mixture in the molding device of FIG. 24. [Figure 26] FIG. 25 is a schematic cross-sectional view showing the filling of the mixture into the mold cavity of the molding apparatus of FIG. 24. [Figure 27] 1 is a flow chart illustrating an injection molding method according to some embodiments of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Different embodiments or examples are disclosed below to illustrate different features of the present invention. In order to easily illustrate the present invention, specific examples of components and arrangements are provided below. Of course, they are illustrative and not intended to be limiting. For example, in the following description, the formation of a first element on a second element may include an embodiment in which the first element and the second element are in direct contact with each other, or an embodiment in which another element is included between the first element and the second element, and the first element and the second element are not necessarily in direct contact with each other. Furthermore, the present invention may repeatedly use reference characters (numbers and / or letters) in different embodiments. This repetition is for the purpose of simplicity and clarity, and does not by itself dictate a relationship between the different embodiments and / or configurations being discussed.

[0012] Additionally, spatially relative terms such as "beneath," "below," "lower," "above," and "upper" may be used herein for ease of description to describe the relationship between one element or feature and another element or feature as shown in the drawings. The spatially relative terms are intended to include various orientations of the device in use or operation in addition to the orientation depicted in the drawings. The device may be oriented differently (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein should be interpreted accordingly.

[0013] Although the numerical ranges and parameters setting forth the broad scope of the invention 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. As used herein, the term "about" generally refers to within 10%, 5%, 1% or 0.5% of a given value or range. Alternatively, the term "about" refers to within the standard error of the sample mean that is acceptable when considered by one of ordinary skill in the art. Except in the working examples / examples, or unless otherwise expressly stated, all numerical ranges, quantities, values, proportions, and the like of materials quantities, lengths of time, temperatures, operating conditions, proportions of amounts, and the like disclosed herein should be understood to be modified in all instances by the term "about". Thus, unless otherwise indicated, the numerical parameters set forth in the invention and the appended claims can be varied as desired. Finally, each numerical parameter should be construed in light of the number of reported significant digits and by applying ordinary roughening techniques. Ranges are expressed herein as from one endpoint to another endpoint, or between two endpoints. All ranges disclosed herein include the endpoints unless otherwise stated.

[0014] 1 is a schematic top view of an injection molding system 1 according to one embodiment of the present invention. The injection molding system 1 may include at least one rail 12, at least one molding station 13, 14, at least one molding device 3, 3', an injection device 2, and an extrusion system 29.

[0015] The extrusion system 29 and the injection device 2 may be disposed on the rail 12 and may move or slide on or along the rail 12 toward the molding device 3, 3'. The extrusion system 29 may be disposed on the injection device 2 and therefore the injection device 2 may move or slide together with the extrusion system 29. However, in some embodiments, the extrusion system 29 may be disposed beside the injection device 2 or the rail 12 and only the injection device 2 may move or slide on or along the rail 12. The extrusion system 29 may be configured to generate a mixture of a polymeric material and a blowing agent and to discharge the mixture into the injection device 2. The extrusion system 29 may be coupled to or communicable with the injection device 2. In some embodiments, the mixture may include a polymeric polymer and a blowing agent. In some embodiments, the blowing agent may be a physical or chemical additive that releases gas during the heating step, thereby forming pores in the foamed polymer molded article obtained after the step. In some embodiments, the blowing agent may be a physical blowing agent. In some embodiments, the blowing agent may be a supercritical fluid (SCF).

[0016] The injection device 2 may include a body portion 21, an extension portion 23, and at least one discharge channel 27. At least one molding station 13, 14 may be arranged beside the rail 12. At least one molding device 3, 3' may be arranged on at least one molding station 13, 14. The number of molding stations 13, 14 and the number of molding devices 3, 3' may be adjusted as needed. In some embodiments, the injection molding system 1 may include multiple molding stations 13, 14 and multiple molding devices 3, 3'. Each molding device 3, 3' may be arranged on each molding station 13, 14. Thus, the molding devices 3, 3' may be arranged side by side along the rail 12.

[0017] FIG. 2 is a schematic cross-sectional view of the injection device 2 taken along line II in FIG. 1. The injection device 2 may include a main body 21, an extension 23, and at least one discharge channel 27. The main body 21 may define the accommodation space 20 by a side wall 22. The extension 23 may extend from the main body 21. Alternatively, the extension 23 may be connected to the main body 21. The extension 23 may define a connection passage 231 in communication with the accommodation space 20. The discharge channel 27 may extend from the extension 23. Alternatively, the discharge channel 27 may be connected to the extension 23. The discharge channel 27 may define a second passage 26 in communication with the connection passage 231 and the accommodation space 20. Thus, the discharge channel 27 may be a branch of the extension 23, and the second passage 26 may be in communication with the accommodation space 20 of the main body 21.

[0018] The discharge channel 27 may include a body portion 24 and an end portion 25. In some embodiments, the body portion 24 and the end portion 25 may be integrally formed as a monolithic or unitary structure. The body portion 24 may have an outer surface 241. The end portion 25 may have an outer surface 251 and an end surface 254. The outer surface 251 of the end portion 25 may be substantially coplanar with the outer surface 241 of the body portion 24. The end surface 254 of the end portion 25 may include a first surface 252 and a second surface 253. The first surface 252 may not be coplanar with the second surface 253. The first surface 252 may intersect with the second surface 253 at an angle greater than 90 degrees. Thus, the end surface 254 of the end portion 25 may be a non-planar surface. The end portion 25 of the discharge channel 27 may have a non-planar end surface 254. The entire end surface 254 of the end portion 25 may not be a flat surface. Furthermore, the first surface 252 may not be coplanar with the outer surface 251. The first surface 252 may be an inclined surface connecting the outer surface 251 and the second surface 253. Thus, the end 25 may taper towards the second surface 253. In some embodiments, the extension of the second surface 253 may be perpendicular to the extension of the outer surface 251.

[0019] As shown in FIG. 2, the second passage 26 may extend through the body 24 and the end 25 and have an opening 264 at the second surface 253. The opening 264 may be a discharge port. In some embodiments, the mixture in the extrusion system 29 may be injected from the receiving space 20 through the connecting passage 231 into the second passage 26 of the discharge channel 27. In some embodiments, one discharge channel 27 may correspond to one extension 23. In some embodiments, one extension 23 may correspond to multiple discharge channels 27. In some embodiments, multiple discharge channels 27 may be connected to or communicate with the extension 23. In some embodiments, each discharge channel 27 may be attached to the extension 23. The number of discharge channels 27 may be adjusted based on the properties of the mixture.

[0020] The discharge channels 27 may extend parallel to each other and be disposed adjacent to each other. In some embodiments, each discharge channel 27 may contain a different amount of the mixture to be ejected from the receiving space 20. The discharge channels 27 may eject the same or different amounts of the mixture to the molding device 3. In some embodiments, each discharge channel 27 may operate under different temperatures. In some embodiments, the discharge channels 27 may have different widths or diameters and therefore different flow rates of the mixture. In some embodiments, the ends 25 of the discharge channels 27 may eject different amounts of the mixture.

[0021] As shown in FIG. 1, the number of molding devices 3, 3' can be adjusted as needed. In some embodiments, multiple molding devices 3, 3' may correspond to one injection device 2. The mixture can flow from the extrusion system 29 through the discharge channel 27 of the injection device 2 into one molding device 3, 3'. Although FIG. 1 shows only two molding devices 3, 3' for clarity and simplicity, this example is for illustrative purposes only and is not intended to limit the embodiments. Those skilled in the art will readily appreciate that any suitable number of molding devices 3, 3' can be utilized, and all combinations thereof are intended to be included within the scope of the embodiments. Furthermore, although the molding devices 3, 3' are shown as having similar features, this is for illustrative purposes and is not intended to limit the embodiments, and the molding devices 3, 3' can have similar or different structures to fulfill the desired functions.

[0022] 3 is a schematic cross-sectional view of a molding apparatus 3 taken along line II-II in FIG. 1. The molding apparatus 3 may have an upper surface 33 and may include an upper mold 31 and a lower mold 32 opposed to the upper mold 31. The molding apparatus 3 (including the upper mold 31 and the lower mold 32) may define a mold cavity 30 and a first passage 36 communicating with the mold cavity 30. Although FIG. 3 shows one molding apparatus 3 including one mold cavity 30 for clarity and simplicity, this example is for illustrative purposes only and is not intended to limit the embodiment. Those skilled in the art will easily understand that one molding apparatus 3 may include multiple mold cavities 30.

[0023] In some embodiments, the mold cavity 30 is defined by an upper mold part 31 and a lower mold part 32. In some embodiments, the upper mold part 31 and the lower mold part 32 are complementary in configuration and are separable from each other. In some embodiments, the lower mold part 32 may define the mold cavity 30, and the upper mold part 31 may have a certain thickness and cover the lower mold part 32 and the mold cavity 30. However, in other embodiments, the lower mold part 32 may define a lower mold cavity, and the upper mold part 31 may define an upper mold cavity opposite to the lower mold cavity. The mold cavity 30 may be formed by the upper mold cavity and the lower mold cavity.

[0024] The upper mold 31 of the molding apparatus 3 may include an inlet portion 37. In some embodiments, the upper mold 31 and the inlet portion 37 may be integrally formed as a unitary or integral structure. A first passageway 36 may extend from the inlet portion 37. Thus, the inlet portion 37 may be in communication with the mold cavity 30. The inlet portion 37 may include an end portion 35. The end portion 35 may define a recess 34 recessed from the upper surface 33 of the molding apparatus 3. The end portion 35 of the inlet portion 37 may have an end surface 354. The end surface 354 of the end portion 35 may include a first surface 352 and a second surface 353. The first surface 352 may not be coplanar with the second surface 353. The first surface 352 may intersect with the second surface 353 at an angle greater than 90 degrees. Thus, the end surface 354 of the end portion 35 may be a non-planar surface. End 35 of inlet portion 37 may have a non-planar end surface 354. The entire end surface 354 of end 35 need not be a flat surface. The entire end surface 354 of end 35 of inlet portion 37 may be non-coplanar with top surface 33 of molding apparatus 3. In some embodiments, end surface 354 (including first surface 352 and second surface 353) of end 35 of inlet portion 37 is recessed from top surface 33 of molding apparatus 3 to define recess 34.

[0025] Furthermore, the first surface 352 may be an inclined surface connecting the top surface 33 and the second surface 353 of the molding device 3. Thus, the recess 34 may taper away from the top surface 33 of the molding device 3. In some embodiments, the first passage 36 may be in communication with the recess 34, and the recess 34 may taper toward the first passage 36. The first passage 36 may have an opening 364 in the second surface 353. The opening 364 may be an injection port or a supply port. Although FIG. 3 shows one molding device 3 including three inlet ports 37 for clarity and simplicity, this example is for illustrative purposes only and is not intended to limit the embodiment. Those skilled in the art will readily appreciate that one molding device 3 may include one or more inlet ports 37 that can be in communication with one mold cavity 30.

[0026] 4 is a schematic top view of the injection molding system of FIG. 1, in which the injection device 2 moves horizontally to a position corresponding to the molding device 3. FIG. 5 is a schematic cross-sectional view of the injection device 2 and the molding device 3 taken along line III-III in FIG. 4. As shown in FIG. 5, the discharge channel 27 may be disposed above the inlet port 37 of the molding device 3. In some embodiments, the second passage 26 or opening 264 of the discharge channel 27 may be aligned with the first passage 36 or opening 364 of the inlet port 37 of the molding device 3. The central axis of the second passage 26 of the discharge channel 27 may be aligned with the central axis of the first passage 36 of the inlet port 37 of the molding device 3.

[0027] The end 25 of the discharge channel 27 may be configured to mate with the end 35 of the inlet 37 of the molding apparatus 3. In some embodiments, the end 25 of the discharge channel 27 and the end 35 of the inlet 37 of the molding apparatus 3 may be interengageable. For example, the end surface 354 of the end 35 of the inlet 37 of the molding apparatus 3 and the end surface 254 of the end 25 of the discharge channel 27 may be configured to be complementary. That is, the contour of the end 25 of the discharge channel 27 may match the contour of the recess 34 of the inlet 37 of the molding apparatus 3.

[0028] 5A is a schematic cross-sectional view of an injection molding system 1, in which an injection device 2 moves horizontally to a position corresponding to a molding device 3. As shown in FIG. 5A, the discharge channel 27 may be disposed above the inlet port 37 of the molding device 3. In some embodiments, the second passage 26 or opening 264 of the discharge channel 27 may be slightly offset from the first passage 36 or opening 364 of the inlet port 37 of the molding device 3. There may be a slight offset between the central axis of the second passage 26 of the discharge channel 27 and the central axis of the first passage 36 of the inlet port 37 of the molding device 3.

[0029] FIG. 6 is a schematic cross-sectional view of an injection molding system 1, in which the injection device 2 moves downward to contact the molding device 3. As shown in FIG. 6, the injection device 2 of FIG. 5 or FIG. 5A may move downward to contact the molding device 3. The end surface 354 of the end 35 of the inlet portion 37 of the molding device 3 and the end surface 254 of the end 25 of the discharge channel 27 may be configured to be complementary, so that the end 35 of the inlet portion 37 of the molding device 3 and the end 25 of the discharge channel 27 may be engaged with each other. In some embodiments, the discharge channel 27 may be received in the inlet portion 37 of the molding device 3. Thus, the end 25 of the discharge channel 27 may be configured to be disposed within the recess 34 of the molding device 3. The end 25 of the discharge channel 27 may fill the recess 34 of the molding device 3. Thus, the end 25 of the discharge channel 27 may be at least partially surrounded by the end 35 of the inlet portion 37 of the molding device 3. Ends 25 of discharge channels 27 may be respectively coupled to ends 35 of inlet ports 37 of molding apparatus 3. The mixture may be transported from discharge channels 27 into a mold cavity 30 of molding apparatus 3. In some embodiments, the mixture is injected into mold cavity 30, where it is subsequently post-formed into a foamed polymeric article.

[0030] The first passage 36 or opening 364 of the molding device 3 may be able to communicate with the second passage 26 or opening 264 of the injection device 2 at the connecting point 15. The connecting point 15 may not be level with the upper surface 33 of the molding device 3. In some embodiments, the height of the connecting point 15 may be lower than the height of the upper surface 33 of the molding device 3.

[0031] An end surface 354 of the end 35 of the inlet 37 of the molding apparatus 3 may contact an end surface 254 of the end 25 of the discharge channel 27 at an interface. For example, the interface may be the end surface 354 of the end 35 of the inlet 37 of the molding apparatus 3 or the end surface 254 of the end 25 of the discharge channel 27. The interface may be non-coplanar with the top surface 33 of the molding apparatus 3. In some embodiments, the interface may be recessed from the top surface 33 of the molding apparatus 3.

[0032] In some embodiments, the molding device 3 may further define a connection point (not shown) that is in communication with the mold cavity 30. The connection point may be configured to allow fluid or gas to enter or exit the mold cavity 30. A gas line (not shown) of a gas source (not shown) may be coupled to the connection point. In some embodiments, the gas source may be configured to supply a fluid or gas, and may supply a suitable fluid or gas as needed. For example, the fluid or gas may be air, an inert gas, etc., but the present invention is not limited thereto. The position, shape, and quantity of the connection points are not particularly limited and may be adjusted as needed. In some embodiments, the connection points are holes. In some embodiments, the connection points are disposed on the inner side wall or the inner bottom wall of the lower mold 32, and penetrate the lower mold 32. In some embodiments, the connection points are configured to supply and release gas.

[0033] The molding device 3 may further include a pressure-sensing unit (not shown) configured to detect the pressure in the mold cavity 30. In some embodiments, the properties of the foamed polymer are affected by the size and distribution of pores in the polymer, where the size and distribution of pores are related to temperature, pressure, and feed rate. The pressure-sensing unit is not limited to a specific type, as long as it can detect pressure and provide information about the pressure after detecting the pressure in the mold cavity 30. When the gas enters and leaves the mold cavity 30, the pressure in the mold cavity 30 needs to be adjusted so that the resulting foamed polymer molded product can have a desired predetermined shape and properties.

[0034] In the present invention, before the mixture is injected into the mold cavity 30, there is a pressure (e.g., 1 atmosphere or more) provided by a gas source in the mold cavity 30. Therefore, leak-tightness between the injection device 2 and the molding device 3 is an important issue. In the embodiment shown in Figs. 1 to 6, the end surface 354 of the end 35 of the inlet portion 37 of the molding device 3 and the end surface 254 of the end 25 of the discharge channel 27 may be configured complementary to each other, so that the end 35 of the inlet portion 37 of the molding device 3 and the end 25 of the discharge channel 27 may be tightly engaged with each other. This can form an excellent leak-tightness between the injection device 2 and the molding device 3. Therefore, air leakage and undesirable pressure drop can be improved.

[0035] Furthermore, as shown in FIG. 5A, the second passage 26 or opening 264 of the discharge channel 27 may be slightly misaligned with the first passage 36 or opening 364 of the inlet 37 of the molding device 3. In the embodiment shown in FIG. 1 to FIG. 6, the design of the first surface 352 of the end 35 of the inlet 37 of the molding device 3 and the first surface 252 of the end 25 of the discharge channel 27 may guide the discharge channel 27 to a desired position during the downward movement of the injection device 2, which may be a self-alignment effect. That is, the injection molding system 1 may include a self-alignment mechanism for aligning the opening 364 of the first passage 36 of the molding device 3 with the opening 264 of the second passage 26 of the injection device 2. The self-alignment mechanism may include the recess 34 of the molding device 3 and the end 25 of the discharge channel 27. As a result, the first passage 36 or opening 364 of the molding device 3 may be aligned with the second passage 26 or opening 264 of the injection device 2, as shown in FIG. 6. That is, by matching the first surface 352 of the end 35 of the injection port 37 of the molding device 3 with the first surface 252 of the end 25 of the discharge channel 27, the positional tolerance between the injection device 2 and the molding device 3 can be corrected. Therefore, the mixture is smoothly injected from the second passage 26 of the discharge channel 27 to the first passage 36 of the molding device 3 without leakage.

[0036] FIG. 6A is a schematic cross-sectional view of an injection molding system 1' according to an embodiment of the present invention. The injection molding system 1' of FIG. 6A may be similar to the injection molding system 1 of FIG. 6, but the discharge channel of the injection molding system 1' may have a different structure and the inlet portion of the injection molding system 1' may have a different structure. As shown in FIG. 6A, at least one discharge channel (e.g., discharge channel 27') may be different from the discharge channel 27. The discharge channel 27' of the injection device 2' may include a body portion 24' and an end portion 25'. The end portion 25' of the discharge channel 27' of the injection device 2' may have a flat end surface 256 perpendicular to the outer surface 241 and / or the outer surface 251. Furthermore, at least one inlet portion (e.g., inlet portion 37') of the molding device 3' may be different from the inlet portion 37. The inlet portion 37' of the molding device 3' may include an end portion 35'. The end 35' of the inlet portion 37' of the molding apparatus 3' may have a flat end surface 356 that is coplanar with the top surface 33 of the molding apparatus 3'. When the end 35' of the inlet portion 37 of the molding apparatus 3' is engaged with the end 25 of the discharge channel 27 of the injection apparatus 2', the flat end surface 256 of the end 25' of the discharge channel 27' may be in intimate contact with the flat end surface 356 of the end 35' of the inlet portion 37', aligning the second passage 26 or opening 264 of the discharge channel 27' with the first passage 36 or opening 364 of the inlet portion 37' of the molding apparatus 3'.

[0037] FIG. 7 is a schematic top view of an injection molding system 1a according to an embodiment of the present invention. The injection molding system 1a may include at least one rail 12, at least one molding station 13, 14, at least one molding device 3a, 3a', an injection device 2a, and an extrusion system 29. The rail 12, molding stations 13, 14, and extrusion system 29 of FIG. 7 may be the same as the rail 12, molding stations 13, 14, and extrusion system 29 of FIG. 1, respectively. The molding device 3a of FIG. 7 may be similar to the molding device 3 of FIG. 1, but with a different structure of the injection inlet portion 37a. The injection device 2a of FIG. 7 may be similar to the injection device 2 of FIG. 1, but with a different structure of the discharge channel 27a.

[0038] FIG. 8 is a schematic cross-sectional view of the injection device 2a taken along line IV-IV of FIG. 7. The injection device 2a may include a body portion 21, an extension portion 23, and at least one discharge channel 27a. The body portion 21 and the extension portion 23 of FIG. 8 may be similar to the body portion 21 and the extension portion 23 of FIG. 2, respectively. The discharge channel 27a may include a body portion 24 and an end portion 25a. In some embodiments, the body portion 24 and the end portion 25a may be different elements. That is, the end portion 25a may be removably attached to the body portion 24. Alternatively, the end portion 25a may be disposed on the body portion 24. In some embodiments, the end portion 25a may be an outlet or ejection nozzle. The structure and contour of the end portion 25a of FIG. 8 may be the same as or similar to the structure and contour of the end portion 25 of FIG. 2. The end portion surface 254 of the end portion 25a may include a first surface 252 and a second surface 253. First surface 252 may not be coplanar with second surface 253. Thus, end surface 254 of end 25a may be a non-planar surface. Second passageway 26 may extend through body portion 24 and end 25a and have an opening 264 in second surface 253.

[0039] FIG. 9 is a schematic cross-sectional view of the molding apparatus 3a taken along line VV in FIG. 7. The molding apparatus 3a may have an upper surface 33 and may include an upper mold 31 and a lower mold 32 facing the upper mold 31. The molding apparatus 3a (including the upper mold 31 and the lower mold 32) may define a mold cavity 30 and a first passage 36 communicating with the mold cavity 30. The molding apparatus 3a may further include an injection port portion 37a embedded or disposed in the through hole 313 of the upper mold 31. Thus, the upper mold 31 and the injection port portion 37a may be different elements. The injection port portion 37a may be a sprue bushing or may be detachable from the upper mold 31. The first passage 36 may extend from the injection port portion 37a. The injection port portion 37a may include an end portion 35a. The end portion 35a may define a recess 34 recessed from the upper surface 33 of the molding apparatus 3a. End 35a of inlet portion 37a may have an end surface 354. End surface 354 of end 35a may include a first surface 352 and a second surface 353. First surface 352 may not be coplanar with second surface 353. Thus, end surface 354 of end 35a may be a non-planar surface.

[0040] The entire end surface 354 of end 35a of inlet portion 37a may be non-coplanar with top surface 33 of molding apparatus 3a. In some embodiments, first passageway 36 may be in communication with recess 34, and recess 34 may taper toward first passageway 36. First passageway 36 may have an opening 364 in second surface 353.

[0041] FIG. 10 is a schematic top view of the injection molding system 1a of FIG. 7, showing the injection device 2a moving horizontally to a position corresponding to the molding device 3a. FIG. 11 is a schematic cross-sectional view of the injection device 2a and the molding device 3a taken along line VI-VI of FIG. 10. As shown in FIG. 11, the discharge channel 27a may be disposed above the inlet 37a of the molding device 3a. In some embodiments, the second passage 26 or opening 264 of the discharge channel 27a may be aligned with the first passage 36 or opening 364 of the inlet 37a of the molding device 3a. The central axis of the second passage 26 of the discharge channel 27a may be aligned with the central axis of the first passage 36 of the inlet 37a of the molding device 3a. In some embodiments, the end 25a of the discharge channel 27a and the end 35a of the inlet 37a of the molding device 3a may be mutually engageable. For example, the end surface 354 of the end 35a of the inlet 37a of the molding device 3a and the end surface 254 of the end 25a of the discharge channel 27a may be configured to be complementary, i.e., the contour of the end 25a of the discharge channel 27a may match the contour of the recess 34 of the inlet 37a of the molding device 3a.

[0042] Figure 12 is a schematic cross-sectional view of the injection molding system 1a of Figure 10, showing the injection device 2a moving downward into contact with the molding device 3a. As shown in Figure 12, the end 35a of the inlet portion 37a of the molding device 3a and the end 25a of the discharge channel 27a may be interengaged.

[0043] FIG. 13 is a schematic cross-sectional view of an injection molding system 1b according to an embodiment of the present invention. FIG. 14 is a schematic cross-sectional view of the injection molding system 1b of FIG. 13, showing the injection device 2b moving downward and contacting the molding device 3b. The injection molding system 1b of FIG. 13 may be similar to the injection molding system 1a of FIG. 11, but the end 25b of the discharge channel 27b of the injection device 2b and the end 35b of the inlet portion 37b of the molding device 3b have different structures. As shown in FIG. 13, the end surface 254b of the end 25b of the discharge channel 27b of the injection device 2b may include a curved surface. For example, the end surface 254b of the end 25b of the discharge channel 27b may include a convex surface. Furthermore, the end surface 354b (or the recess 34b) of the end 35b of the inlet portion 37b of the molding device 3b may include a curved surface. For example, the end surface 354b of the end 35b of the inlet portion 37b of the molding device 3b may include a concave surface. As shown in Fig. 14, the end surface 354b including the concave surface of the end 35b (or the recess 34b) of the inlet portion 37b of the molding device 3b may match the end surface 254b including the convex surface of the end 25b of the discharge channel 27b. Thus, the end 35b of the inlet portion 37b of the molding device 3b may be engaged with the end 25b of the discharge channel 27b.

[0044] FIG. 15 is a schematic cross-sectional view of an injection molding system 1c according to an embodiment of the present invention. FIG. 16 is a schematic cross-sectional view of the injection molding system 1c of FIG. 15, showing the injection device 2c moving downward and contacting the molding device 3c. The injection molding system 1c of FIG. 15 may be similar to the injection molding system 1a of FIG. 11, but differs in the structure of the end 25c of the discharge channel 27c of the injection device 2c and the end 35c of the inlet portion 37c of the molding device 3c. As shown in FIG. 15, the end 25c of the discharge channel 27c of the injection device 2c may define a recess 28 and have an end surface 254c. The end surface 254c of the end 25c may include a first surface 252, a second surface 253, and a third surface 255. The third surface 255 may be a bottom surface of the end 25c of the discharge channel 27c. The recess 28 may be recessed from the third surface 255 and may be defined by the first surface 252 and the second surface 253. The recess 28 may be in communication with the second passage 26. The first surface 252, the second surface 253, and the third surface 255 may not be coplanar with each other. The first surface 252 may intersect with the second surface 253 at an angle greater than 90 degrees. Thus, the end surface 254c of the end 25c may be a non-planar surface. The end 25c of the discharge channel 27c may have a non-planar end surface 254c. The entire end surface 254c of the end 25c may not be a flat surface.

[0045] The end 35c of the inlet 37c of the molding device 3c may include a protrusion 38 protruding from the upper surface 33 of the molding device 3c. The protrusion 38 may have an end surface 354c. The end surface 354c of the protrusion 38 of the end 35c may include a first surface 352 and a second surface 353. The first surface 352, the second surface 353, and the upper surface 33 may not be coplanar with each other. The first surface 352 may intersect with the second surface 353 at an angle greater than 90 degrees. Thus, the end surface 354c of the end 35c of the inlet 37c may be a non-planar surface and may protrude from the upper surface 33 of the molding device 3c. Furthermore, the first passage 36 may extend through the protrusion 38 of the molding device 3c, and the contour of the protrusion 38 of the molding device 3c may match the contour of the recess 28 of the discharge channel 27c. In some embodiments, the first passageway 36 or opening 364 of the molding device 3c may be communicable with the second passageway 26 or opening 264 of the injection device 2c at the connecting point 15. As shown in Fig. 16, the height of the connecting point 15 may be higher than the height of the upper surface 33 of the molding device 3c. Furthermore, the self-alignment mechanism of the injection molding system 1c may include a recess 28 of the discharge channel 27c and a protrusion 38 of the molding device 3c.

[0046] FIG. 17 is a schematic cross-sectional view of an injection molding system 1d according to an embodiment of the present invention. FIG. 18 is a schematic cross-sectional view of the injection molding system 1d of FIG. 17, showing the injection device 2d moving downward and contacting the molding device 3d. The injection molding system 1d of FIG. 17 may be similar to the injection molding system 1c of FIG. 15, but the end 25d of the discharge channel 27d of the injection device 2d and the end 35d of the inlet portion 37d of the molding device 3d are different in structure. As shown in FIG. 17, the end surface 254d (or the recess 28) of the end 25d of the discharge channel 27d of the injection device 2d may include a curved surface. For example, the end surface 254d of the end 25d of the discharge channel 27d may include a concave surface. Furthermore, the end surface 354d (or the protrusion 38) of the end 35d of the inlet portion 37d of the molding device 3d may include a curved surface. For example, the end surface 354d of the end 35d of the inlet portion 37d of the molding device 3d may include a convex surface. As shown in Fig. 18, the end surface 354d of the end 35d of the inlet portion 37d of the molding device 3d including the convex surface may match the end surface 254d of the end 25d of the discharge channel 27d including the concave surface. Thus, the end 35d of the inlet portion 37d of the molding device 3d may be engaged with the end 25d of the discharge channel 27db.

[0047] FIG. 19 is a schematic cross-sectional view of an injection molding system 1e according to an embodiment of the present invention. FIG. 20 is a schematic cross-sectional view of the injection molding system 1e of FIG. 19, showing the injection device 2e moving downward and contacting the molding device 3e. The injection molding system 1e of FIG. 19 may be similar to the injection molding system 1c of FIG. 15, but differs in the structure of the end 25e of the discharge channel 27e of the injection device 2e and the end 35e of the inlet portion 37e of the molding device 3e. As shown in FIG. 19, the end 25e of the discharge channel 27e of the injection device 2e may define a recess 28e and may have an end surface 254e. The recess 28e may be recessed from the third surface 255 and defined by the first surface 252. Thus, the end surface 254e of the end 25e may include the first surface 252 and the third surface 255. The recess 28e does not have to be in communication with the second passage 26. The recess 28e may be a positioning hole or an annular groove.

[0048] The end 35e of the inlet portion 37e of the molding device 3e may include a protrusion 38e protruding from the upper surface 33 of the molding device 3e. The protrusion 38e may have an end surface 354e. The end surface 354e of the protrusion 38e of the end 35e may include a first surface 352 and a second surface 353. The first passage 36 may not extend through the protrusion 38e of the molding device 3e. The protrusion 38e may be a locating pin or an annular wall. The contour of the protrusion 38e of the molding device 3e may match the contour of the recess 28e of the discharge channel 27e.

[0049] FIG. 21 is a schematic cross-sectional view of an injection molding system 1f according to an embodiment of the present invention. FIG. 22 is a schematic cross-sectional view of the injection molding system 1f of FIG. 21, showing the injection device 2f moving downward and contacting the molding device 3f. The injection molding system 1f of FIG. 21 may be similar to the injection molding system 1c of FIG. 15, but differs in the structure of the end 25f of the discharge channel 27f of the injection device 2f and the end 35f of the inlet portion 37f of the molding device 3f. As shown in FIG. 21, the end 25f of the discharge channel 27f of the injection device 2f may have a non-flat end surface 254f. There may be protrusions and recesses on the end surface 254f. Furthermore, the end 35f of the inlet portion 37f of the molding device 3f may have a non-flat end surface 354f. There may be protrusions and recesses on the end surface 354f. The contour of the non-flat end surface 354f of the end 35f of the inlet portion 37f of the molding device 3f may match the contour of the non-flat end surface 254f of the end 25f of the discharge channel 27f of the injection device 2f, and thus the non-flat end surface 354f of the end 35f may contact or engage the non-flat end surface 254f of the end 25f.

[0050] FIG. 23 is a schematic top view of an injection molding system 1g according to an embodiment of the present invention. FIG. 24 is a schematic cross-sectional view of a molding apparatus 3g taken along line VII-VII in FIG. 23. The injection molding system 1g in FIG. 23 may be similar to the injection molding system 1a in FIG. 10, but the structures of the molding apparatuses 3g, 3g' are different. The molding apparatus 3g in FIG. 24 may be similar to the molding apparatus 3a in FIG. 11, but the dimensions of the mold cavity 30g defined by the upper mold 31g and the lower mold 32g are different. As shown in FIG. 24, the mold cavity 30g may include a first portion 301 and a second portion 302. The first portion 301 may have a first depth D1, and the second portion 302 may have a second depth D2, where the first depth D1 may be smaller than the second depth D2. For example, the depth of the mold cavity 30g may increase from the left side to the right side. Inlet portion 37a may be closer to first portion 301 than to second portion 302. That is, inlet portion 37a may be located at a position corresponding to a relatively small depth of mold cavity 30g. Alternatively, inlet portion 37a may be located closer to a portion of mold cavity 30g having a minimum depth than to a portion of mold cavity 30g having a maximum depth.

[0051] FIG. 25 is a schematic cross-sectional view showing the flow of the mixture 60 in the molding apparatus 3g of FIG. 24. FIG. 26 is a schematic cross-sectional view showing the filling of the mixture 60 into the mold cavity 30g of the molding apparatus 3g of FIG. 24. As shown in FIG. 24, the mixture 60 may enter the first portion 301 of the mold cavity 30g through the discharge channel 27a and the inlet portion 37a. Then, the mixture 60 may flow toward the second portion 302 of the mold cavity 30g as shown in FIG. 25. Then, the mixture 60 may be filled into the mold cavity 30g. Since the mixture 60 flows from the narrow portion (e.g., the first portion 301) to the wide portion (e.g., the second portion 302), there is less resistance and the mixture 60 can flow smoothly. Therefore, the obtained foamed polymer molded product has better quality such as a desired shape and properties.

[0052] 27 is a flow chart illustrating an injection molding method according to some embodiments of the present invention. As shown in FIG 27, an injection molding method 50 may include the following steps.

[0053] In some embodiments, the molding method 50 may include a step S51 of providing a molding apparatus that defines a mold cavity and includes an inlet portion communicating with the mold cavity. For example, as shown in FIG. 3, a molding apparatus 3 is provided. The molding apparatus 3 may include an upper mold 31 and a lower mold 32 that faces the upper mold 31. The molding apparatus 3 (including the upper mold 31 and the lower mold 32) may define a mold cavity 30 and a first passage 36 that communicates with the mold cavity 30. The upper mold 31 of the molding apparatus 3 may include an inlet portion 37. The inlet portion 37 may include an end portion 35. The first passage 36 may extend from the inlet portion 37. Thus, the inlet portion 37 may be in communication with the mold cavity 30. The first passage 36 may have an opening 364 in an end surface 354 of the end portion 35 of the inlet portion 37.

[0054] In some embodiments, the molding method 50 may include a step S52 of providing an injection device including a discharge channel. For example, as shown in FIG. 2, an injection device 2 is provided. The injection device 2 may include a body portion 21, an extension portion 23, and at least one discharge channel 27. The body portion 21 may define a receiving space 20 by a sidewall 22. The extension portion 23 may extend from the body portion 21. The extension portion 23 may define a connecting passage 231 that is in communication with the receiving space 20. The discharge channel 27 may extend from the extension portion 23. The discharge channel 27 may define a second passage 26 that is in communication with the connecting passage 231 and the receiving space 20. The discharge channel 27 may include a body portion 24 and an end portion 25. The end portion 25 may have an end surface 254. The second passageway 26 may extend through the body portion 24 and the end portion 25 and have an opening 264 in the end surface 254 of the end portion 25 .

[0055] In some embodiments, the molding method 50 may include a step S53 of engaging an end of the inlet portion with an end of the discharge channel, whereby an opening of the second passage defined by the discharge channel and an opening of the first passage defined by the inlet portion are self-aligned. For example, as shown in Figures 5 and 6, an end surface 354 of an end 35 of the inlet portion 37 of the molding device 3 and an end surface 254 of an end 25 of the discharge channel 27 may be configured to be complementary, so that the end 35 of the inlet portion 37 of the molding device 3 and the end 25 of the discharge channel 27 may be engaged with each other. In some embodiments, an opening 264 of the second passage 26 or the second passage 26 of the discharge channel 27 and an opening 364 of the first passage 36 or the first passage 36 of the inlet portion 37 of the molding device 3 may be self-aligned.

[0056] The foregoing description outlines features of several embodiments to enable those skilled in the art to better understand aspects of the present invention. Those skilled in the art will be able to use the present invention as a basis for designing or modifying other processes and structures to carry out the same purposes and / or achieve the same advantages as the embodiments described herein. Those skilled in the art will also understand that such equivalent structures do not depart from the spirit and scope of the present invention, and that various changes, substitutions, and alterations of the present invention are possible without departing from the spirit and scope of the present invention.

[0057] Moreover, the scope of the present invention is not intended to be limited to the particular embodiments of the processes, machines, manufacture, compositions of matter, means, methods, and steps described herein. As will be readily apparent to one of ordinary skill in the art from this disclosure, there are other now existing or later developed processes, machines, manufacture, compositions of matter, means, methods, or steps that perform substantially the same function or achieve substantially the same results as the corresponding embodiments described herein that can be utilized in accordance with the present invention. Accordingly, it is intended that the appended claims include within their scope such processes, machines, manufacture, compositions of matter, means, methods, and steps. [Explanation of symbols]

[0058] 1, 1', 1a, 1b, 1c, 1d, 1e, 1f, 1g Injection molding system 12 Rail 13, 14 Molding stations 15 Connection point 2, 2', 2a, 2b, 2c, 2d, 2e, 2f, 2g Injection device 20 Accommodation space 21 Main body part 22 Side wall 23 Extension part 231 Connection path 24, 24' Main body part 241 Outer surface 25, 25', 25a, 25b, 25c, 25d, 25e, 25f End part 251 Outer surface 252 First surface 253 Second surface 254, 254b, 254c, 254d, 254e, 254f End surface 255 Third surface 256 End surface 26 Second passage 264 Opening 27, 27', 27a, 27b, 27c, 27d, 27e, 27f Discharge channel 28, 28e Recess 29 Extrusion system 3, 3', 3a, 3b, 3c, 3d, 3e, 3f, 3g, 3g' Molding device 30, 30g Mold cavity 301 First part 302 Second part 31, 31g Upper mold 32, 32g Lower mold 33 Upper surface 34 Recess 35, 35', 35a, 35b, 35c, 35d, 35e, 35f End part 352 First surface 353 Second surface 3 54, 354b, 354c, 354d, 354e, 354f End surface surface 36 1st aisle 364 Aperture 37, 37', 37a, 37b, 37c, 37d, 37e, 37f Inlet section 38, 38e protrusion 50 Molding method 60 mixture D1 First Depth D2 Second Depth

Claims

1. 1. An injection molding system comprising: A molding device; an injection device, the molding apparatus defines a mold cavity and includes an inlet section communicating with the mold cavity, the inlet section including an end having an end surface, the end surface of the inlet section having first, second and third surfaces that are non-coplanar with respect to one another, the first surface connecting the second and third surfaces, the mold cavity including a first portion having a first depth and a second portion having a second depth, the first depth being less than the second depth, the inlet section being closer to the first portion than the second portion; the injection device includes an outlet channel, the outlet channel including an end having an end surface, the end surface of the outlet channel having a first surface, a second surface, and a third surface that are non-coplanar with respect to one another, the first surface connecting the second surface and the third surface; the first surface of the end surface of the outlet channel entirely contacts the first surface of the end surface of the inlet section, and the second surface of the end surface of the outlet channel entirely contacts the second surface of the end surface of the inlet section; the third surface of the end surface of the outlet channel perpendicularly intersects the third surface of the end surface of the inlet port; In a cross-sectional view, a length of the first surface of the end surface of the outlet channel is equal to a length of the first surface of the end surface of the inlet section, and a width of the second surface of the end surface of the outlet channel is equal to a width of the second surface of the end surface of the inlet section. An injection molding system comprising:

2. the molding device further defines a first passage extending from the inlet portion and communicating with the mold cavity, the injection device further defines a receiving space, and the discharge channel defines a second passage communicating with the receiving space, the injection molding system further includes a self-alignment mechanism for aligning an opening of the first passage of the molding device with an opening of the second passage of the injection device; 2. The injection molding system of claim 1, wherein the first passage has a constant width and the second passage has a constant width, the width of the first passage being equal to the width of the second passage.

3. 3. The injection molding system of claim 2, wherein the self-alignment mechanism includes a recess of the molding device and the end of the discharge channel, the recess being recessed from a surface of the molding device and connected to the first passage, and the shape of the end of the discharge channel matches the shape of the recess.

4. the molding apparatus further defines a connection point in communication with the mold cavity, the connection point being configured to allow fluid or gas to enter or exit the mold cavity; The injection molding system of claim 2 , wherein the molding apparatus further comprises a pressure sensing unit configured to detect a pressure in the mold cavity.

5. The injection molding system of claim 1, characterized in that the first surface of the end surface of the discharge channel intersects with the second surface of the end surface of the discharge channel at a first angle greater than 90 degrees, and the first surface of the end surface of the injection inlet portion intersects with the second surface of the end surface of the injection inlet portion at a second angle greater than 90 degrees, and the first angle is equal to the second angle.

6. The injection molding system of claim 1, characterized in that the end of the injection inlet portion defines a recess recessed from an upper surface of the molding apparatus, and the maximum width of the recess is equal to the maximum width of the discharge channel.

7. The injection molding system of claim 1, characterized in that the molding apparatus further includes an additional injection inlet portion connected to the mold cavity, the additional injection inlet portion including an end having an end surface, the injection apparatus further includes an additional discharge channel, the additional discharge channel including an end having an end surface, the end surface of the end of the additional discharge channel engages with the end surface of the end of the additional injection inlet portion, the structure of the end of the additional discharge channel differs from the structure of the end of the discharge channel, and the structure of the end of the additional injection inlet portion differs from the structure of the end of the injection inlet portion.

8. 1. A method of injection molding comprising the steps of: providing a molding apparatus defining a mold cavity and including an inlet portion in communication with the mold cavity, the inlet portion including an end having an end surface, the end surface of the inlet portion having a first surface and a second surface that is non-coplanar with the first surface; providing an injection apparatus comprising a discharge channel, the discharge channel including an end having an end surface, the end surface of the discharge channel having a first surface and a second surface that is non-coplanar with the first surface, the mold cavity including a first portion having a first depth and a second portion having a second depth, the first depth being less than the second depth, the inlet portion being closer to the first portion than to the second portion; engaging the end of the inlet portion with the end of the outlet channel, wherein an opening of a second passage defined by the outlet channel and an opening of a first passage defined by the inlet portion are self-aligned, and the first surface of the end surface of the outlet channel is generally in contact with the first surface of the end surface of the inlet portion and the second surface of the end surface of the outlet channel is generally in contact with the second surface of the end surface of the inlet portion, wherein in a cross-sectional view, a length of the first surface of the end surface of the outlet channel is equal to a length of the first surface of the end surface of the inlet portion and a width of the second surface of the end surface of the outlet channel is equal to a width of the second surface of the end surface of the inlet portion; providing pressure to the mold cavity; injecting the mixture into the mold cavity through the injection device; 1. An injection molding method comprising:

9. 9. The injection molding method of claim 8, characterized in that the end surface of the ejection channel further has a third surface connecting the first surfaces of the end surfaces of the ejection channel, the end surface of the inlet portion further has a third surface connecting the first surfaces of the end surfaces of the inlet portion, and the third surface of the end surface of the ejection channel perpendicularly intersects with the third surface of the end surface of the inlet portion.

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