Injection molding system and injection molding method

Abstract

To provide an injection molding system and an injection molding method that improve the properties and quality of foamed polymer articles.SOLUTION: An injection molding system includes a supply unit configured to supply a flowable mixture, an injection unit including a discharge port configured to discharge the flowable mixture, a molding apparatus configured to receive the flowable mixture from the discharge port and including a mold cavity and a supply port communicable with the mold cavity and engageable with the discharge port, and a support apparatus disposed between the injection unit and the molding apparatus and configured to facilitate engagement of the injection unit with the molding apparatus. The support apparatus includes a first element connected to the injection unit and a second element disposed on the molding apparatus. The second element includes a first slot configured to receive a protruding portion of the first element, and the protruding portion of the first element is slidable within and along the first slot of the second element.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Provisional Application No. 63 / 379,255, filed October 12, 2022, and U.S. Patent Application No. 18 / 451,073, filed August 16, 2023, each of which is incorporated by reference in its entirety.

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

[0003] The expanded polymer article has many advantages, such as high strength, light weight, impact resistance, good sound insulation and heat insulation, etc. The expanded polymer article can be molded into a molded article having a predetermined shape by injection molding or extrusion molding. For example, a polymer material is melted and mixed with a blowing agent in an extrusion system to form a flowable mixture, and then the mixture is injected or extruded into a molding device to form a desired expanded polymer article. The properties and quality of the expanded polymer article can be improved by adjusting the structure of the injection molding system and adjusting the injection molding system. Summary of the Invention

[0004] SUMMARY OF THE PRESENT EMBODIMENT One object of the present invention is to provide an injection molding system and method.

[0005] According to one embodiment of the present disclosure, an injection molding system is disclosed, the injection molding system comprising: a supply unit configured to supply a flowable mixture of a polymeric material and a blowing agent; injection a dispensing unit including an outlet disposed distally from the supply unit and configured to discharge the flowable mixture. injectiona molding apparatus configured to receive the flowable mixture from the discharge port, the molding apparatus including a mold cavity and an opening in communication with the mold cavity and in corresponding engagement with the discharge port; injection and a support device configured to facilitate engagement of the unit with the molding device. injection a first element connected to the unit and a second element disposed on the molding apparatus, the second element including a slot configured to receive a protruding portion of the first element, the protruding portion of the first element being slidable within and along the slot of the second element.

[0006] According to one embodiment of the present disclosure, a method of injection molding is disclosed, the method comprising the steps of providing an injection molding system, the injection molding system comprising: injection a molding unit and a molding device, injection The unit is liquidity mixture and a discharge port configured to discharge the fluid from the discharge port. mixture a mold cavity configured to receive the nozzle and including an opening in communication with the mold cavity and correspondingly engageable with the outlet; injection providing a support device configured to facilitate engagement of the unit with the molding device, the support device comprising: injection a first element connected to the unit and a second element disposed on the molding device; aligning a protruding portion of the first element with a slot of the second element; injection displacing the unit to slide the protruding portion of the first element along the slot of the second element; engaging the outlet with the opening when the protruding portion of the first element engages with the slot of the second element; mixture into the mold cavity. [Brief description of the drawings]

[0007] Aspects of the present disclosure are best understood from the following detailed description when read in conjunction with the accompanying drawing figures. It should be noted that, according to standard practice in the industry, various features have not been drawn to scale. In fact, dimensions of various features may be arbitrarily expanded or reduced for clarity of discussion.

[0008] [Figure 1] FIG. 1 is a schematic diagram of an injection molding system according to some embodiments of the present disclosure. [Diagram 2] FIG. 1 is a schematic diagram illustrating a portion of an injection molding system according to some embodiments of the present disclosure. [Diagram 3] FIG. 1 is a schematic top view illustrating a portion of an injection molding system according to some embodiments of the present disclosure. [Figure 4] FIG. 1 is a schematic diagram illustrating a portion of an injection molding system according to some embodiments of the present disclosure. [Diagram 5] 1 is a schematic cross-sectional view illustrating a portion of an injection molding system according to some embodiments of the present disclosure. [Figure 6] 1 is a flowchart illustrating an injection molding method according to some embodiments of the present disclosure. [Figure 7] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 8] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 9] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 10] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 11] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 12] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 13] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 14] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 15] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 16] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 17] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 18] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 19] FIG. 1 is a schematic diagram of an injection molding system according to some embodiments of the present disclosure. [Figure 20] FIG. 1 is a schematic diagram illustrating a portion of an injection molding system according to some embodiments of the present disclosure. [Figure 21] FIG. 1 is a schematic top view illustrating a portion of an injection molding system according to some embodiments of the present disclosure. [Figure 22] FIG. 1 is a schematic diagram illustrating a portion of an injection molding system according to some embodiments of the present disclosure. [Figure 23] 1 is a schematic cross-sectional view illustrating a portion of an injection molding system according to some embodiments of the present disclosure. [Figure 24] 1 is a flowchart illustrating an injection molding method according to some embodiments of the present disclosure. [Diagram 25]1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 26] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 27] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 28] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 29] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Diagram 30] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Diagram 31] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Diagram 32] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Diagram 33] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Diagram 34] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Diagram 35] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Diagram 36] 1A-1D are side or cross-sectional schematic views of an injection molding system during one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 37] 1 is a flowchart illustrating an injection molding method according to some embodiments of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] The following disclosure provides many different embodiments or examples for implementing different features of the present invention. Specific examples of components and arrangements are described below to simplify the disclosure. These are, of course, merely examples and are not intended to be limiting. For example, in the following description, a first feature formed above or on a second feature may include an embodiment in which the first and second features are formed in direct contact, and may also include an embodiment in which an additional feature may be formed between the first and second features such that the first and second features are not in direct contact. Furthermore, the disclosure may repeat reference numbers and / or letters in various examples. This repetition is for the purpose of simplicity and clarity and does not, in itself, dictate a relationship between the various embodiments and / or configurations discussed.

[0010] Additionally, spatially relative terms such as "below," "under," "lower," "upper," "top," and the like may be used herein to describe the relationship of one element or feature to another element or feature as illustrated in the figures for ease of description. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

[0011] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present disclosure are approximations, the numerical values ​​set forth in the specific examples are reported as precisely as possible. However, any numerical value inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Also, as used herein, the term "about" generally means within 10%, 5%, 1%, or 0.5% of a given value or range. Alternatively, the term "about" means within an acceptable standard error of the mean as would be considered by one of ordinary skill in the art. Other than in the operational / working examples, or unless otherwise indicated, all numerical ranges, amounts, values, and percentages, such as amounts of materials, durations, temperatures, operating conditions, ratios of amounts, and the like, disclosed herein, should be understood in all instances to be modified by the term "about". Thus, unless indicated to the contrary, the numerical parameters set forth in the present disclosure and appended claims are approximations that may vary as desired. At the very least, each numerical parameter should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Ranges can be expressed herein as from one endpoint to another endpoint, or between two endpoints. All ranges disclosed herein include the endpoints unless otherwise stated.

[0012] Generally, the appearance and physical properties of the foamed polymer article are directly affected by the injection molding process, and therefore the design of the injection molding system must take into account the injection conditions of the flowable mixture from the injection unit into the molding device, so that the flowable mixture can be completely and effectively injected into the molding device to form a foamed polymer article with the desired qualities.

[0013] FIG. 1 illustrates a schematic perspective view of a first injection molding system 100 according to an embodiment of the present disclosure. In some embodiments, referring to FIG. 1, the first injection molding system 100 includes an injection unit 101 and a molding apparatus 102. The injection unit 101 is engageable with the molding apparatus 102. In some embodiments, the first injection molding system 100 further includes a flowable mixture supply unit 103 in communication with the injection unit 101. In some embodiments, the flowable mixture supply unit 103 generates a flowable mixture, injection The unit 101 is configured to supply

[0014] In some embodiments, the flowable mixture includes a polymeric material, such as ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), etc. In some embodiments, the flowable mixture includes a recyclable material. In some embodiments, the flowable mixture further includes a blowing agent. In some embodiments, the blowing agent can be any type of chemical or physical blowing agent known to those skilled in the art. In some embodiments, the blowing agent is a supercritical fluid. The supercritical fluid may include an inert gas, such as carbon dioxide or nitrogen, in a supercritical state. In some embodiments, the flowable mixture includes a polymeric material in a molten state and a blowing agent in a liquid or supercritical fluid state mixed with the polymeric material. In some embodiments, the flowable mixture is a molding material.

[0015] In some embodiments, the flowable mixture supply unit 103 of the first injection molding system 100 includes an extruder (not shown) for converting the polymeric material to a molten state and a mixer (not shown) for mixing the blowing agent into the polymeric material. The polymeric material is capable of flowing from the extruder into the mixer.

[0016] In some embodiments, injection The unit 101 includes an injector 101a. In some embodiments, multiple injectors 101a may be used. injectionThe fluid mixture may be included in the fluid supply unit 103. In some embodiments, the injector 101a is configured to receive the fluid mixture from the fluid mixture supply unit 103 and to discharge the fluid mixture from the outlet 101c. In some embodiments, the injector 101a is in the configuration of an outlet channel, and the outlet 101c is disposed distal to the injector 101a and configured to discharge the fluid mixture.

[0017] In some embodiments, the injector 101a is in communication with a mixer or flowable mixture supply unit 103. In some embodiments, the flowable mixture is discharged from the injector 101a into the molding apparatus 102. The injector 101a is engageable with the molding apparatus 102. The injector 101a is extendable towards the molding apparatus 102 and retractable from the molding apparatus 102. In some embodiments, the injector 101a is extendable / retractable perpendicularly in a first direction as indicated by arrow A. In some embodiments, the injector 101a is extendable / retractable by a hydraulic mechanism 101e. In some embodiments, the hydraulic mechanism 101e is attached to the injector 101a. In some embodiments, the hydraulic mechanism 101e is disposed between the flowable mixture supply unit 103 and the injector 101a.

[0018] In some embodiments, the support apparatus 105 is configured to facilitate engagement between the injection unit 101 and the molding apparatus 102. In some embodiments, the support apparatus 105 is disposed on the molding apparatus 102. In some embodiments, the support apparatus 105 includes a first element 101b disposed adjacent to the injector 101a. In some embodiments, the first element 101b includes: injection unit 101. The first element 101b is extendable towards and retractable from the molding apparatus 102. In some embodiments, the first element 101b is extendable / retractable perpendicular to the second direction as indicated by arrow B. In some embodiments, the first direction and the second direction are parallel.

[0019] In some embodiments, the first element 101b is extendable / retractable along a rail 101f by a motor (not shown) or the like. In some embodiments, the rail 101f is disposed between the flowable mixture supply unit 103 and the first element 101b. In some embodiments, the injector 101a and the first element 101b are extendable / retractable independently of each other. The injector 101a and the first element 101b are displaceable relative to each other. In some embodiments, the injector 101a and the first element 101b can be displaced separately or consistently. In some embodiments, the first element 101b is T-shaped. In some embodiments, the first element 101b includes a protruding portion 101d that is engageable with the molding device 102. In some embodiments, the protruding portion 101d of the first element 101b is disposed distal to the flowable mixture supply unit 103.

[0020] In some embodiments, injection The unit 101 is disposed above a molding apparatus 102. In some embodiments, the injector 101a and the first element 101b are disposed above the molding apparatus 102. In some embodiments, the molding apparatus 102 is configured to receive the flowable mixture discharged from the injector 101a through the discharge port 101c.

[0021] In some embodiments, the molding apparatus 102 includes a first mold 102c and a second mold 102d that is engageable with the first mold 102c. In some embodiments, the first mold 102c is an upper mold and the second mold 102d is a lower mold. In some embodiments, the molding apparatus 102 includes a mold cavity (not shown) defined by the first mold 102c and the second mold 102d, and an opening (not shown) that is in communication with the mold cavity and correspondingly engageable with the outlet 101c.

[0022] FIG. 2 shows a schematic perspective view of the second element 102s of the support device 105, and FIG. 3 shows a schematic top view of the second element 102s. In some embodiments, referring to FIGS. 1-3, the support device 105 includes a second element 102s disposed on the molding device 102 and engageable with the first element 101b. In some embodiments, the second element 102s is engageable with the molding device 102. In some embodiments, the second element 102s is engageable with the first mold 102c. In some embodiments, the second element 102s is removably attached to the molding device 102. In some embodiments, the second element 102s includes a slot 102e defined by a protrusion 102f.

[0023] In some embodiments, the slot 102e and the protrusion 102f are laterally elongated. injection The protrusion 102f is configured to receive the protruding portion 101d of the first element 101b of the unit 101. The protruding portion 101d of the first element 101b is engageable with the protrusion 102f. In some embodiments, the protruding portion 101d of the first element 101b is slidable along the slot 102e of the second element 102s. In some embodiments, the length L1 of the slot 102e is equal to the width W1 of the second element 102s. In some embodiments, the height H1 of the slot 102e is greater than the thickness T1 of the protruding portion 101d of the first element 101b. In some embodiments, the protrusion 102f includes a first portion 102x and a second portion 102y, and the protruding portion 101d of the first element 101b is disposed between the first portion 102x and the second portion 102y of the protrusion 102f.

[0024] In some embodiments, the second element 102s includes a groove 102g configured to receive the outlet 101e. In some embodiments, the groove 102g is disposed on the second element 102s and elongates laterally along the second element 102s. In some embodiments, the groove 102g is parallel to the protrusion 102f and the slot 102e. In some embodiments, the groove 102g is disposed between the first portion 102x and the second portion 102y of the protrusion 102f. The groove 102g is injection The second element 102s is configured to receive the outlet 101c or end of the injector 101a of the unit 101. The outlet 101c or end of the injector 101a is slidable along and within the groove 102g. In some embodiments, an opening 102h is disposed within the groove 102g. The opening 102h extends through the second element 102s.

[0025] In some embodiments, the outlet 101c or end of the injector 101a is receivable by the opening 102h. The outlet 101c or end of the injector 101a is movable within the opening 102h. In some embodiments, the width W3 of the opening 102h is substantially greater than the width W2 of the outlet 101c of the injector 101a. In some embodiments, the width W3 of the opening 102h is equal to the width W2 of the outlet 101c of the injector 101a.

[0026] In some embodiments, the width W4 of the groove 102g is substantially greater than the width W3 of the opening 102h. In some embodiments, a step 102k is formed in the groove 102g adjacent to the opening 102h. In some embodiments, the outlet 101c or end of the injector 101a may be positioned on the step 102k while the molding device 102 is receiving the flowable mixture. In some embodiments, the width W3 of the opening 102h is substantially less than the width W2 of the outlet 101c of the injector 101a, and the outlet 101c or end of the injector 101a may be positioned on the step 102k when the outlet 101c or end of the injector 101a is engaged with the second element 102s. In some embodiments, the outlet 101c covers the opening 102h when the outlet 101c or end of the injector 101a is engaged with the second element 102s.

[0027] In some embodiments, the first sensor 102l is disposed in the slot 102e and configured to sense contact between the protruding portion 101d of the first element 101b and the second element 102s. In some embodiments, the first sensor 102l is disposed at the central end of the slot 102e. In some embodiments, the first sensor 102l is disposed in the slot 102e adjacent to the opening 102h. The first sensor 102l is not particularly limited as long as it can sense pressure and provide pressure information. In some embodiments, a plurality of first sensors 102l are disposed in the slot 102e and the first sensors 102l are configured to sense the position and contact of the protruding portion 101d and the slot 102e. The number and arrangement of the plurality of first sensors 102l are not particularly limited and can be disposed, for example, anywhere on the protrusion 102f in the slot 102e. However, the present invention is not limited thereto.

[0028] In some embodiments, the second sensor 102m is disposed in the groove 102g and configured to sense contact between the outlet 101c and the molding device 102. In some embodiments, the second sensor 102m is disposed in the groove 102g adjacent to the opening 102h. The second sensor 102m is not particularly limited as long as it can sense pressure and provide pressure information. In some embodiments, a plurality of second sensors 102m are disposed in the groove 102g, and the second sensors 102m are configured to sense the position and contact between the outlet 101c and the groove 102g. The number and arrangement of the plurality of second sensors 102m are not particularly limited and can be disposed anywhere in the groove 102g, for example. However, the present invention is not limited thereto.

[0029] In some embodiments, the molding apparatus 102 can be in an open state and a closed state. The first die 102c engages with the second die 102d when the molding apparatus 102 is in the closed state. Figure 4 shows a schematic perspective view of the molding apparatus 102 in the closed state, and Figure 5 shows a schematic cross-sectional view of the molding apparatus 102 in the closed state.

[0030] In some embodiments, referring to FIG. 4 and FIG. 5, when the molding apparatus 102 is in a closed state, the first mold 120c and the second mold 102d define a mold cavity 102i. In some embodiments, the mold cavity 102i is configured to receive the flowable mixture from the injector 101a through the opening 102h of the second element 102s. The mold cavity 102i is accessible only through the supply port 102j when the molding apparatus 102 is in a closed state. The mold cavity 102i is accessible through a gap (not shown) between the first mold 102c and the second mold 102d when the molding apparatus 102 is in an open state. In some embodiments, the molding apparatus 102 includes a supply port 102j that can communicate with the mold cavity 102i. In some embodiments, the supply port 102j is disposed in and passes through the first mold 102c. In some embodiments, the opening 102h is aligned with the feed port 102j when the second element 102s is positioned on the molding apparatus 102, such that the flowable mixture can flow from the injector 101a through the opening 102h and the feed port 102j into the mold cavity 102i. In some embodiments, the opening 102h overlaps with the feed port 102j when the second element 102s is positioned on the molding apparatus 102 in a top view.

[0031] In some embodiments, the molding apparatus 102 may be disposed on a carrier (not shown) and moved with the carrier. In some embodiments, multiple molding apparatus 102 are disposed on the carrier, and the molding apparatus 102 are arranged in a line, row, column, arc, curve, or any other suitable arrangement. In some embodiments, the carrier is rotatable.

[0032] In some embodiments, referring again to FIGS. 1, 2 and 3, the support device 105 may include: injectionThe unit 101 further includes a third element 101g connected thereto, the second element 102s being configured to receive the first element 101b and the third element 101g. In some embodiments, the first element 101b and the third element 101g are both configured to be received by the first portion 102x and the second portion 102y of the protrusion 102f.

[0033] In some embodiments, the third element 101g is disposed adjacent to the injector 101a. In some embodiments, the third element 101g is injection The injector 101a is connected to the unit 101. In some embodiments, the injector 101a is disposed between the first element 101b and the third element 101g. The third element 101g is engageable with the second element 102s. The third element 101g is extendable towards and retractable from the second element 102s. In some embodiments, the third element 101g is extendable / retractable perpendicular to the second direction as indicated by arrow B.

[0034] In some embodiments, the third element 101g is extendable / retractable along the rail 101f by a motor (not shown) or the like. In some embodiments, the rail 101f is disposed between the flowable mixture supply unit 103 and the third element 101g. In some embodiments, the third element 101g and the first element 101b are extendable / retractable independently of each other. The third element 101g and the first element 101b are displaceable relative to each other. In some embodiments, the third element 101g and the injector 101a are extendable / retractable independently of each other. The third element 101g and the injector 101a are displaceable relative to each other. In some embodiments, the third element 101g and the first element 101b can be displaced separately or consistently. In some embodiments, the third element 101g is T-shaped. In some embodiments, the third element 101g includes a protruding portion 101h that can engage with the second element 102s. In some embodiments, the protruding portion 101h is engageable with the slot 102e. In some embodiments, the protruding portion 101h of the third element 101g is disposed distal to the flowable mixture supply unit 103. In some embodiments, the configuration of the third element 101g is similar to or different from the configuration of the first element 101b.

[0035] Also disclosed in the present disclosure is a first injection molding method 200. The first injection molding method 200 includes several operations, and the description and illustration are not to be considered as limiting the order of the operations. FIG. 6 is an embodiment of the first injection molding method 200. In some embodiments, the first injection molding method 200 includes several operations (201-212). FIGS. 7-18 are schematic cross-sectional views of various stages of the first injection molding method according to some embodiments of the present disclosure. In some embodiments, the first injection molding method 200 is performed by the first injection molding system 100 shown in FIGS. 1-5 and described above.

[0036] In operation 201, referring to FIG. injectionA first injection molding system 100 is provided that includes a unit 101, a molding device 102, and a support device 105. In some embodiments, the first injection molding system 100, as described above, injection The unit 101 includes a molding device 102 and a support device 105. The molding device 102 is in a closed state. The opening 102h of the second element 102s is aligned with the feed port 102j of the molding device 102, so that the mold cavity 102i is accessible through the opening 102h and the feed port 102j. In some embodiments, the molding device 102 may be disposed on a carrier (not shown) and moved with the carrier. In some embodiments, several molding devices 102 are disposed on the carrier.

[0037] In operation 202, the protruding portion 101d of the first element 101b of the support device 105 is aligned with the slot 102e of the second element 102s of the support device 105. In operation 203, the outlet 101c is aligned with the groove 102g of the second element 102s configured to receive the outlet 101c. In some embodiments, the alignment of the protruding portion 101d of the first element 101b with the slot 102e of the second element 102s and the alignment of the outlet 101c with the groove 102g are performed simultaneously. In some embodiments, the molding device 102 is positioned below the second element 102s during the alignment of the protruding portion 101d of the first element 101b with the slot 102e of the second element 102s.

[0038] In some embodiments, the injector 101a and the first element 101b are vertically displaced along arrows A and B, respectively, to horizontally align with the groove 102g and the slot 102e, respectively, as shown in FIG. 7. In some embodiments, the injector 101a moves upwards or downwards to horizontally align the outlet 101c with the groove 102g. In some embodiments, the first element 101b moves upwards or downwards to horizontally align the protruding portion 101d with the slot 102e. Alternatively or simultaneously, the second element 102s is displaced along arrows C and / or D to horizontally align with the protruding portion 101d of the first element 101b and the outlet 101c or end of the injector 101a. In some embodiments, the second element 102s is displaced upward, downward, forward, or backward to horizontally align the slot 102e with the protruding portion 101d and the groove 102g with the outlet 101c or end of the injector 101a.

[0039] In some embodiments, the protruding portion 101h of the third element 101g is aligned with the slot 102e of the second element 102s. In some embodiments, the process of aligning the protruding portion 101h of the third element 101g with the slot 102e of the second element 102s is similar to the process of aligning the protruding portion 101d of the first element 101b with the slot 102e of the second element 102s, so repeated description will be omitted for the sake of brevity. In some embodiments, the alignment of the protruding portion 101d of the first element 101b with the slot 102e of the second element 102s and the alignment of the protruding portion 101h of the third element 101g with the slot 102e are performed simultaneously.

[0040] In operation 204, referring to FIG. 8 and FIG. 9, the second element 102s is injection The protruding portion 101d of the first element 101b is caused to slide along the slot 102e of the second element 102s, displacing it towards the unit 101. In action 205, the outlet 101c slides into the groove 102g.

[0041] In some embodiments, after horizontal alignment, the second element 102s may be aligned along arrow E as shown in FIG. injection unit 101. Alternatively, after horizontal alignment, injection The unit 101 is moved along arrow L towards the second element 102s as shown in Figure 8. In some embodiments, the molding device 102 is injection After aligning the unit 101 horizontally, the second element 102s and injection is moved towards unit 101. In other words, injection With the unit 101 and the second element 102s fixed relative to the forming device 102, the forming device 102 is movable.

[0042] FIG. 9 is a schematic cross-sectional view of the first injection molding system 100 of FIG. 8. In some embodiments, the protruding portion 101d of the first element 101b slides along the slot 102e, and the outlet 101c or end of the injector 101a slides along the groove 102g. In some embodiments, the protruding portion 101h of the third element 101g slides along the slot 102e. As shown in FIG. 9, the protrusion 102f is disposed opposite the protruding portion 101d of the first element 101b. In some embodiments, the protruding portion 101d of the first element 101b and the protruding portion 101h of the third element 101g are disposed between the first portion 102x and the second portion 102y of the protrusion 102f.

[0043] In some embodiments, in operations 204 and 205, the first element 101b, the third element 101g, and the injector 101a are not in contact with the second element 102s. In some embodiments, the outlet 101c or end of the injector 101a is surrounded by the groove 102g and is not in contact with the step 102k in the groove 102g. In some embodiments, the first distance D1 between the bottom surface of the protruding portion 101d and the second element 102s is substantially greater than the second distance D2 between the outlet 101c and the bottom surface of the groove 102g.

[0044] In operation 206, injectionThe unit 101 and the support device 105 are displaced and positioned above the molding device 102. In some embodiments, referring to FIG. 10, after aligning the injector 101a with the opening 102h and the injector 101a, the first element 101b moves toward the molding device 102 along the arrow F as shown in FIG. 10. In some embodiments, the molding device 102 is moved until the support device 105 overlaps the molding device 102 and the injector 101a is vertically aligned with the feed port 102j of the molding device 102. In some embodiments, the molding device 102 is moved by rotating a carrier (not shown) that carries the molding device 102.

[0045] In operation 207, referring to FIG. 11, the outlet 101c extends towards the molding device 102, engaging the outlet 101c with the opening 102h.

[0046] In some embodiments, after aligning the injector 101a with the opening 102h, the injector 101a and the first element 101b move toward the molding device 102 along arrow F, as shown in FIG. 11, until the outlet 101c of the injector 101a contacts the second element 102s. In some embodiments, the outlet 101c engages the opening 102h and contacts the step 102k. In some embodiments, the injector 101a and the first element 101b are moved consistently. When the outlet 101c of the injector 101a contacts the second element 102s, the entire first element 101b is still not in contact with the second element 102s, as shown in FIG. 11. In some embodiments, the third element 101g (not shown in FIG. 11) and the first element 101b are moved consistently in operation 207. In some embodiments, contact between the second element 102s and the outlet 101c is sensed by a second sensor 102m disposed in the groove 102g. In some embodiments, contact between the second element 102s and the outlet 101c is sensed continuously.

[0047] 12, in operation 208, the first element 101b is displaced away from the second element 102s while the first element 101b is received by the second element 102s. In some embodiments, the protruding portion 101d of the first element 101b is moved to abut the protrusion 102f of the second element 102s while the protruding portion 101d of the first element 101b is received by the slot 102e of the second element 102s.

[0048] In some embodiments, after the outlet 101c contacts the second element 102s, the first element 101b moves away from the second element 102s along arrow G, as shown in FIG. 12, until the protruding portion 101d of the first element 101b contacts the protrusion 102f of the second element 102s. In some embodiments, the injector 101a remains stationary as the first element 101b moves upward, as shown in FIG. 12. As a result, the first element 101b engages with the second element 102s. In some embodiments, the contact between the second element 102s and the first element 101b is sensed by a first sensor 102l disposed on the protrusion 102f and in the slot 102e. In some embodiments, the contact between the second element 102s and the first element 101b is sensed by the first sensor 102l. In some embodiments, contact between the protrusion 102f and the protruding portion 101d of the first element 101b is sensed by the first sensor 102l. In some embodiments, contact between the second element 102s and the first element 101b is sensed continuously.

[0049] In some embodiments, the third element 101g (not shown in FIG. 12, but shown in FIG. 8) and the first element 101b are moved consistently in operation 208. In some embodiments, the protruding portion 101h (not shown in FIG. 12, but shown in FIG. 8) of the third element 101g is moved to abut the protrusion 102f of the second element 102s while the protruding portion 101h of the third element 101g is received by the slot 102e of the second element 102s. In some embodiments, contact between the protruding portion 101h of the third element 101g and the protrusion 102f of the second element 102s is sensed by the first sensor 102l.

[0050] In operation 209, with reference to FIG. 13, the flowable mixture 104 is injected into a mold cavity 102i of a molding apparatus 102.

[0051] In some embodiments, after the protruding portion 101d contacts the protrusion 102f, the flowable mixture 104 is injected into the mold cavity 102i as shown in FIG. 13. The flowable mixture 104 is discharged from the outlet 101c of the injector 101a through the opening 102h and the supply port 102j of the molding apparatus 102 into the mold cavity 102i. In some embodiments, the flowable mixture 104 is supplied by a flowable mixture supply unit 103 connected to the injector 101a. In some embodiments, the composition of the flowable mixture 104 is similar to the flowable mixture prepared by the supply unit 103 as discussed above, and repeated description will be omitted for the sake of brevity.

[0052] In some embodiments, during injection of the flowable mixture 104, the outlet 101c engages with the opening 102h and contacts the step 102k, and the protruding portion 101d of the first element 101b abuts the protrusion 102f of the second element 102s. During injection of the flowable mixture 104 by the injector 101a into the mold cavity 102i, an injection force I is generated towards the second element 102s and / or the molding device 102. In some embodiments, the injection force I acts on the second element 102s and / or the molding device 102 to move the second element 102s and / or the molding device 102 away from the mold cavity 102i. injection The protrusion 102f pushes the unit 101 away from the mold cavity 102, resulting in a reaction force C acting on the protruding portion 101d by the protrusion 102f. The protruding portion 101d abuts against the protrusion 102f during injection of the flowable mixture 104. Thus, the engagement of the first element 101b with the second element 102s as well as the engagement of the outlet 101c with the supply port 102j are ensured. The flowable mixture 104 flowing out of the mold cavity 102i can be minimized or even prevented.

[0053] In operation 210, referring to FIG. 14, the first element 101b is mixture After injection of 104, the protruding portion 101d of the first element 101b is displaced toward the second element 102s. mixture After injection of 104, the protruding portion 101d of the first element 101b is received by the slot 102e of the second element 102s while being disengaged from the protrusion 102f of the second element 102s.

[0054] In some embodiments, after injection of the flowable mixture 104, the first element 101b is displaced toward the second element 102s along arrow H as shown in FIG. 14 until the first element 101b disengages from the second element 102s. In some embodiments, the protruding portion 101d is moved away from the protrusion 102f. In some embodiments, the first element 101b is moved toward the molding device 102 and disengages from the protrusion 102f. In some embodiments, the injector 101a remains stationary as the first element 101b moves downward as shown in FIG. 14. In some embodiments, the separation of the protrusion 102f and the protruding portion 101d of the first element 101b is sensed by the first sensor 102l.

[0055] In some embodiments, the third element 101g (not shown in FIG. 14, but shown in FIG. 8) and the first element 101b are moved consistently in the operation 210. In some embodiments, the protruding portion 101h of the third element 101g (not shown in FIG. 14, but shown in FIG. 8) is moved in a flowable manner. mixture The protrusion 102f of the second element 102s is displaced toward the second element 102s after injection of 104. In some embodiments, the separation of the protruding portion 101h of the third element 101g and the protrusion 102f of the second element 102s is sensed by the first sensor 102l.

[0056] In operation 211, referring to FIG. 15, the injector 101a is displaced away from the molding device 102. In some embodiments, the outlet 101c is mixture After injection of 104, the molding device 102 is retracted away from the molding device.

[0057] In some embodiments, after disengagement of the first element 101b from the second element 102s, the injector 101a moves away from the molding device 102 along arrow J, as shown in FIG. 15, until the outlet 101c of the injector 101a is no longer in contact with the second element 102s. In some embodiments, the separation of the injector 101a and the groove 102g is sensed by the second sensor 102m. In some embodiments, the injector 101a and the first element 101b move away from the molding device 102 along arrow J. In some embodiments, the injector 101a and the first element 101b are moved consistently. In some embodiments, the injector 101a, the first element 101b, and the third element 101g are moved consistently.

[0058] In operation 212, referring to FIGS. 16 and 17, the second element 102s and the molding device 102: injection displaced away from unit 101, or injection The unit 101 is displaced away from the forming device 102 .

[0059] In some embodiments, after disengaging the first element 101b and the injector 101a from the second element 102s, the second element 102s and the molding device 102 may: injection Alternatively, after disengaging the first element 101b and the injector 101a from the second element 102s, injectionThe unit 101 is displaced away from the molding device 102. In some embodiments, the second element 102s and the molding device 102 move horizontally away from the first element 101b and the injector 101a along arrow K, as shown in FIG. 16. Alternatively, the first element 101b and the injector 101a move horizontally away from the second element 102s and the molding device 102 along arrow M, as shown in FIG. 16. FIG. 17 shows the second element 102s moving horizontally away from the molding device 102 along arrow M, as shown in FIG. injection After being displaced away from unit 101, injection The unit 101 and the second element 102s are shown separated from each other.

[0060] In operation 212, referring to FIG. 18, the forming device 102 is displaced away from the second element 102s or the second element 102s is displaced away from the forming device 102.

[0061] In some embodiments, after disengaging the forming device 102 from the second element 102s, the forming device 102 is displaced away from the second element 102s. In some embodiments, the forming device 102 is displaced away from the second element 102s by rotating a carrier (not shown) that is held or placed under the forming device 102. Alternatively, after disengaging the second element 102s from the forming device 102, injection The unit 101, the forming device 102 and the second element 102s are separated from each other. In some embodiments, the forming device 102 is moved horizontally away from the second element 102s. Alternatively, the second element 102s moves horizontally away from the forming device 102. Figure 18 shows that the second element 102s and the forming device 102 are separated from each other after the forming device 102 has moved away from the second element 102s.

[0062] 19 shows a schematic perspective view of a second injection molding system 300 according to one embodiment of the present disclosure. In some embodiments, referring to FIG. 19, the second injection molding system 300 includes: injection A unit 101, a molding device 102, injection and a support device 105 disposed between the unit 101 and the molding device 102. In some embodiments, the second injection molding system 300 includes: injection The unit 101 further includes a flowable mixture supply unit 103 in communication with the unit 101. In some embodiments, the flowable mixture supply unit 103 generates a flowable mixture, injection The flowable mixture is configured to be delivered to unit 101. In some embodiments, the flowable mixture comprises a polymeric material, such as ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), and the like. In some embodiments, the flowable mixture comprises a recyclable material. In some embodiments, the flowable mixture further comprises a blowing agent.

[0063] In some embodiments, the flowable mixture supply unit 103 of the second injection molding system 300 includes an extruder (not shown) for converting the polymeric material to a molten state and a mixer (not shown) for mixing the blowing agent into the polymeric material. The polymeric material is capable of flowing from the extruder into the mixer.

[0064] In some embodiments, injectionThe unit 101 includes several injectors 101a arranged between a first element 101b and a third element 101g of the support device 105. In some embodiments, the support device 105 surrounds the injectors 101a. In some embodiments, each of the injectors 101a is configured to receive the flowable mixture from the flowable mixture supply unit 103 and to discharge the flowable mixture from its outlet 101c. In some embodiments, each of the injectors 101a can be in communication with a mixer or with the flowable mixture supply unit 103. In some embodiments, the flowable mixture is discharged from the injectors 101a into the molding device 102. Each of the injectors 101a can be engaged with a second element 102s of the support device 105. In some embodiments, the injectors 101a are all engaged with the second element 102s. In some embodiments, each of the injectors 101a can be extended / retracted perpendicularly to a first direction, as indicated by arrow A. In some embodiments, the injectors 101a are extendable / retractable independently of each other. In some embodiments, each of the injectors 101a is extendable / retractable by a hydraulic mechanism 101e. In some embodiments, the movement of each injector 101a is actuated and controlled by one hydraulic mechanism 101e.

[0065] In some embodiments, the support device 105 includes: injectionThe support device 105 is configured to facilitate engagement of the unit 101 with the molding device 102. In some embodiments, the support device 105 includes a first element 101b, a third element 101g disposed adjacent to the injector 101a, and a second element 102s disposed on the molding device 102. In some embodiments, the first element 101b and the third element 101g are engageable with the second element 102s. The first element 101b and the third element 101g are extendable toward the molding device 102 and retractable from the molding device 102, respectively. In some embodiments, each of the first element 101b and the third element 101g is extendable / retractable vertically in a manner as indicated by a second direction as indicated by arrow B. In some embodiments, each of the first element 101b and the third element 101g is extendable / retractable along the rail 101f by a motor (not shown) or the like. In some embodiments, each of the first element 101b and the third element 101g is moved along a rail 101f, and the movement of each of the first element 101b and the third element 101g is actuated and controlled by one motor. In some embodiments, the first direction and the second direction are parallel.

[0066] In some embodiments, the injector 101a, the first element 101b, and the third element 101g are extendable / retractable independently of each other. The injector 101a, the first element 101b, and the third element 101g are displaceable relative to each other. In some embodiments, the injector 101a, the first element 101b, and the third element 101g can be displaced separately or consistently. In some embodiments, all the injectors 101a are moved consistently relative to each other, and the first element 101b and the third element 101g are moved consistently relative to each other. In some embodiments, each of the first element 101b and the third element 101g is T-shaped. In some embodiments, the first element 101b includes a protruding portion 101d that can be engaged with the second element 102s, and the third element 101g includes a protruding portion 101h that can be engaged with the second element 102s.

[0067] In some embodiments, injection The unit 101 is disposed above a molding apparatus 102. In some embodiments, the injector 101a, the first element 101b, and the third element 101g are disposed above the molding apparatus 102. In some embodiments, the molding apparatus 102 is configured to receive the flowable mixture discharged from the injector 101a through the discharge port 101c.

[0068] In some embodiments, the molding apparatus 102 includes a first mold 102c and a second mold 102d that is engageable with the first mold 102c. In some embodiments, the first mold 102c is an upper mold and the second mold 102d is a lower mold. In some embodiments, the second element 102s is engageable with the first mold 102c. In some embodiments, the molding apparatus 102 may be disposed on a carrier (not shown) and moved with the carrier. In some embodiments, multiple molding apparatuses 102 are disposed on the carrier, and the molding apparatuses are arranged in a line, row, column, arc, curve, or any other suitable arrangement. In some embodiments, the carrier is rotatable.

[0069] FIG. 20 shows a schematic perspective view of the second element 102s, and FIG. 21 shows a schematic top view of the second element 102s. In some embodiments, referring to FIGS. 19-21, the support device 105 includes a second element 102s engageable with the first element 101b and the third element 101g. In some embodiments, the second element 102s is disposed on the molding device 102. In some embodiments, the second element 102s includes a slot 102e defined by a protrusion 102f and a slot 102o defined by a protrusion 102p.

[0070] In some embodiments, the slots 102e, 102o and the protrusions 102f, 102p are elongated in the transverse direction. The slot 102e is configured to receive the protruding portion 101d of the first element 101b of the support device 105. The slot 102o is configured to receive the protruding portion 101f of the third element 101g of the support device 105. In some embodiments, the protruding portion 101d of the first element 101b is slidable along and within the slot 102e of the second element 102s, and the protruding portion 101f of the third element 101g is slidable along and within the slot 102o of the second element 102s. In some embodiments, each of the length L1 of the slot 102e and the length L2 of the slot 102o is equal to the width W1 of the second element 102s. In some embodiments, a height H1 of the slot 102e of the second element 102s is greater than a thickness T1 of the protruding portion 101d of the first element 101b, and a height H2 of the slot 102o of the second element 102s is greater than a thickness T2 of the protruding portion 101h of the third element 101g. In some embodiments, each of the protruding portion 101d of the first element 101b and the protruding portion 101h of the third element 101g is T-shaped and configured to be received by the slot 102e and the slot 102o, respectively.

[0071] In some embodiments, the molding device 102 includes a groove 102g configured to receive the outlet 101e. In some embodiments, the groove 102g is disposed on the second element 102s and elongates laterally along the second element 102s. In some embodiments, the groove 102g is parallel to the protrusions 102f and 102p. The groove 102g is injectionThe opening 102h is configured to receive the outlet 101c or end of the injector 101a of the unit 101. The outlet 101c or end of the injector 101a is slidable along the groove 102g. In some embodiments, the opening 102h is disposed in the groove 102g. In some embodiments, the opening 102h extends through the second element 102s. The outlet 101c or end of the injector 101a is receivable by the opening 102h. The outlet 101c or end of the injector 101a is movable within the opening 102h. In some embodiments, the width W3 of the opening 102h is substantially greater than the total width W2 of the outlets 101c of the injector 101a. In some embodiments, all the outlets 101c of the injector 101a are receivable by the opening 102h.

[0072] In some embodiments, the first sensor 102l is disposed in the slot 102e and configured to sense contact between the protruding portion 101d and the slot 102e, and the third sensor 102q is disposed in the slot 102o and configured to sense contact between the protruding portion 101h and the slot 102o. In some embodiments, the first sensor 102l is disposed at a central end of the slot 102e, and the third sensor 102q is disposed at a central end of the slot 102o. The first sensor 102l and the third sensor 102q are not particularly limited as long as they can sense pressure and provide pressure information.

[0073] In some embodiments, a plurality of first sensors 102l are disposed in the slot 102e, and the first sensors 102l are configured to sense the position and contact of the protruding portion 101d and the slot 102e. In some embodiments, a plurality of third sensors 102q are disposed in the slot 102o, and the third sensors 102q are configured to sense the position and contact of the protruding portion 101h and the slot 102o. The number and arrangement of the plurality of third sensors 102q are not particularly limited, and can be disposed, for example, anywhere on the protrusion 102p or in the slot 102o. However, the present invention is not limited thereto.

[0074] In some embodiments, the step 102k is formed in the groove 102g adjacent to the opening 102h. In some embodiments, the second sensor 102m is disposed in the groove 102g and configured to sense contact between the outlet 101c and the groove 102g.

[0075] In some embodiments, the second sensor 102m is disposed in the opening 102h. The second sensor 102m is not particularly limited as long as it can sense pressure and provide pressure information. In some embodiments, a plurality of second sensors 102m are disposed in the opening 102h, and the second sensors 102m are configured to sense the position and contact of the discharge port 101c and the molding device 102. The number and arrangement of the plurality of second sensors 102m are not particularly limited, and can be disposed anywhere in the opening 102h, for example. However, the present invention is not limited thereto.

[0076] In some embodiments, the molding apparatus 102 can be in an open state and a closed state. The first mold 102c engages with the second mold 102d when the molding apparatus 102 is in the closed state. FIG. 22 shows a schematic perspective view of the molding apparatus 102 in the closed state, and FIG. 23 shows a schematic cross-sectional view of the molding apparatus 102 in the closed state. In some embodiments, a mold cavity 102i is defined by the first mold 102c and the second mold 102d when the molding apparatus 102 is in the closed state. In some embodiments, the first mold 102c and the second mold 102d define a plurality of mold cavities 102i. In some embodiments, the mold cavities 102i are isolated from each other. In some embodiments, the mold cavity 102i is configured to receive the flowable mixture from the injector 101a through the opening 102h and the supply port 102j of the second element 102s. The mold cavity 102i is accessible only through the supply port 102j when the molding apparatus 102 is in a closed state. The mold cavity 102i is accessible through a gap (not shown) between the first mold 102c and the second mold 102d when the molding apparatus 102 is in an open state. In some embodiments, the molding apparatus 102 includes a supply port 102j that can communicate with the mold cavity 102i. In some embodiments, the supply port 102j is disposed in and passes through the first mold 102c. In some embodiments, the molding apparatus 102 includes several supply ports 102j, as shown in FIG. 22 and FIG. 23. The supply ports 102j correspond to the mold cavities 102i, respectively. In some embodiments, the openings 102h are aligned with the feed ports 102j when the second element 102s is placed on the molding apparatus 102, so that the flowable mixture can flow from the injector 101a through the openings 102h and the feed ports 102j into the mold cavity 102i. In some embodiments, the openings 102h are located above all of the feed ports 102j. In some embodiments, the openings 102h overlap with the feed ports 102j when the second element 102s is placed on the molding apparatus 102 in a top view.

[0077] Also disclosed in the present disclosure is a second injection molding method 400. The second injection molding method 400 includes several operations, and the description and illustration are not to be considered as limiting the order of the operations. FIG. 24 is an embodiment of the second injection molding method 400. In some embodiments, the second injection molding method 400 includes several operations (401-413). FIGS. 25-36 are schematic cross-sectional views of various stages of the second injection molding method according to some embodiments of the present disclosure. In some embodiments, the second injection molding method 400 is performed by the second injection molding system 300 as shown in FIGS. 19-23 and discussed above.

[0078] In operation 401, referring to FIG. injection A second injection molding system 300 is provided that includes the unit 101, the molding device 102, and the support device 105. In some embodiments, the second injection molding system 300 includes, as described above, injection The second element 102s includes a unit 101, a molding device 102, and a support device 105. The molding device 102 is in a closed state. The openings 102h of the second element 102s are aligned with some of the feed ports 102j of the molding device 102, so that the mold cavities 102i are accessible through the openings 102h and the feed ports 102j.

[0079] In operation 402, the protruding portion 101d of the first element 101b of the support device 105 is aligned with the first slot 102e of the second element 102s of the support device 105. In operation 403, the protruding portion 101h of the third element 101g of the support device is aligned with the second slot 102e of the second element 102s. In operation 404, the plurality of outlets 101c are aligned with the groove 102g of the second element 102s configured to receive the outlets 101c. In some embodiments, the alignment of the protruding portion 101d of the first element 101b with the first slot 102e of the second element 102s, the alignment of the protruding portion 101h of the third element 101g with the second slot 102e of the second element 102s, and the alignment of the outlets 101c with the groove 102g are performed simultaneously.

[0080] In some embodiments, as shown in FIG. 25, the injector 101a is displaced vertically along arrow A to align horizontally with the groove 102g, and the first element 101b and the third element 101g are displaced vertically along arrow B to align horizontally with the first slot 102e and the second slot 102e, respectively. In some embodiments, the injector 101a moves upward or downward to align horizontally with the groove 102g. In some embodiments, the first element 101b and the third element 101g move upward or downward to align horizontally with the first slot 102e and the second slot 102e, respectively. Alternatively or simultaneously, the molding device 102 is displaced along arrows C and / or D to align horizontally with the protruding portion 101d of the first element 101b, the protruding portion 101h of the third element 101g, and the outlet 101c or end of the injector 101a. In some embodiments, the molding device 102 moves upward, downward, forward, and / or backward to horizontally align the first slot 102e with the protruding portion 101d, horizontally align the second slot 102e with the protruding portion 101h, and horizontally align the groove 102g with the outlet 101c or end of the injector 101a.

[0081] In operation 405, referring to FIG. 26 and FIG. 27, injection The unit 101 is displaced to slide the protruding portion 101d of the first element 101b along the first slot 102e of the second element 102s and to slide the protruding portion 101h of the third element 101g along the second slot 102e of the second element 102s. In operation 406, the outlet 101c slides into the groove 102g.

[0082] In some embodiments, after being horizontally aligned, the second element 102s may be aligned along arrow E as shown in FIG. injection unit 101. Alternatively, after being aligned horizontally, injectionThe unit 101 is moved toward the second element 102s along the arrow L as shown in FIG. 26. FIG. 27 is a schematic cross-sectional view of the second injection molding system 300 of FIG. 26. In some embodiments, the first element 101b slides along the first slot 102e, the third element 101g slides along the second slot 102e, and the outlet 101c or end portion of the injector 101a slides along the groove 102g. In some embodiments, the second element 102s is moved until the first element 101b is located in the first slot 102e, the third element 101g is located in the second slot 102e, and the outlet 101c or end portion of the injector 101a is vertically aligned with the opening 102h. As shown in FIG. 27, the protrusion 102f is disposed opposite the protruding portion 101d of the first element 101b, and the protrusion 102p is disposed opposite the protruding portion 101h of the third element 101g. The first element 101b, the third element 101g, and the injector 101a are not in contact with the second element 102s. In some embodiments, the outlet 101c of the injector 101a is aligned with the opening 102h, respectively. In some embodiments, the distance D3 between the bottom surface of the protruding portion 101h and the second element 102s is substantially greater than the distance D4 between the end of the outlet 101c and the top surface of the molding device 102.

[0083] In operation 407, the molding apparatus 102: injectionThe unit 101 and the support device 105 are displaced toward the support device 105 and positioned below the support device 105. In some embodiments, referring to FIG. 28, after aligning the injector 101a with the opening 102h, the injector 101a and the first element 101b are moved toward the molding device 102 along the arrow F as shown in FIG. 28. In some embodiments, the molding device 102 is moved until the support device 105 covers the molding device 102 and the injector 101a is vertically aligned with the feed port 102j of the molding device 102. In some embodiments, the molding device 102 is moved by moving, for example by rotating, a carrier (not shown) positioned below the molding device 102. In some embodiments, the molding device 102 is moved until the discharge port 101c or end of the injector 101a is vertically aligned with the feed port 102j of the molding device 102.

[0084] In operation 408, referring to FIG. 29, the outlet 101c extends towards the molding device 102, engaging the outlet 101c with the molding device 102.

[0085] In some embodiments, after aligning the injector 101a with the opening 102h, the injector 101a, the first element 101b, and the third element 101g move toward the molding device 102 along arrow F as shown in FIG. 28 until the outlet 101c of the injector 101a contacts the second element 102s. In some embodiments, the outlet 101c contacts the first mold 102c. In some embodiments, the injector 101a, the first element 101b, and the third element 101g are moved consistently. When the outlet 101c of the injector 101a contacts the first mold 102c, the entire first element 101b and the entire third element 101g still do not contact the second element 102s as shown in FIG. 29. In some embodiments, the contact between the molding device 102 and the outlet 101c is sensed by a second sensor 102m disposed in the groove 102g. In some embodiments, contact between the shaping device 102 and the outlet 101c is sensed continuously.

[0086] 30, in operation 409, the first element 101b and the third element 101g are displaced away from the second element 102s while the first element 101b and the third element 101g are received by the second element 102s. In some embodiments, the protruding portion 101d of the first element 101b moves to abut the protrusion 102f of the second element 102s while the protruding portion 101d of the first element 101b is received by the first slot 102e of the second element 102s, and the protruding portion 101h of the third element 101g moves to abut the protrusion 102p of the second element 102s while the protruding portion 101h of the third element 101g is received in the second slot 102e of the second element 102s.

[0087] In some embodiments, after the outlet 101c contacts the molding device 102, the first element 101b and the third element 101g move away from the second element 102s along arrow G as shown in FIG. 30 until the protruding portion 101d of the first element 101b and the protruding portion 101h of the third element 101g contact the protrusions 102f and 102p of the second element 102s, respectively. In some embodiments, the injector 101a remains stationary as the first element 101b and the third element 101g move upward as shown in FIG. 30. As a result, the first element 101b and the third element 101g engage with the second element 102s.

[0088] In some embodiments, contact between the second element 102s and the first element 101b is sensed by the first sensor 102l. In some embodiments, contact between the protrusion 102f and the protruding portion 101d of the first element 101b is sensed by the first sensor 102l. In some embodiments, contact between the second element 102s and the first element 101b is sensed continuously. In some embodiments, contact between the second element 102s and the third element 101g is sensed by a third sensor 102q disposed on the protrusion 102p and in the second slot 102e. In some embodiments, contact between the second element 102s and the third element 101g is sensed by the third sensor 102q. In some embodiments, contact between the protrusion 102p and the protruding portion 101h of the third element 101g is sensed by the third sensor 102q. In some embodiments, contact between the second element 102s and the third element 101g is sensed continuously.

[0089] In operation 410, with reference to FIG. 31, the flowable mixture 104 is injected into the mold cavity 102i of the molding apparatus 102.

[0090] In some embodiments, after the protruding portion 101d contacts the protrusion 102f and the protruding portion 101h contacts the protrusion 102p, the flowable mixture 104 is injected into the mold cavity 102i as shown in FIG. 31. The flowable mixture 104 is discharged from the outlet 101c of the injector 101a through the opening 102h and the supply port 102j into the mold cavity 102i. In some embodiments, the flowable mixture 104 is supplied by a flowable mixture supply unit 103 connected to the injector 101a. In some embodiments, the composition of the flowable mixture 104 is similar to the flowable mixture prepared by the supply unit 103 as discussed above, and repetitive description will be omitted for the sake of brevity.

[0091] In some embodiments, during injection of the flowable mixture 104, the outlet 101c engages the molding apparatus 102, the protruding portion 101d of the first element 101b abuts the protrusion 102f of the second element 102s, and the protruding portion 101h of the third element 101g abuts the protrusion 102p of the fourth element 102o. During injection of the flowable mixture 104 by the injector 101a into the mold cavity 102i, an injection force I is generated towards the molding apparatus 102. In some embodiments, the injection force I acts on the molding apparatus 102 to move the molding apparatus 102 away from the mold cavity 102i. injection The unit 101 is pushed away from the mold cavity 102i, which results in the generation of a reaction force C acting on the protruding portion 101d by the protrusion 102f. During injection of the flowable mixture 104, the protruding portion 101d abuts against the protrusion 102f, and the protruding portion 101h abuts against the protrusion 102p. Thus, the engagement between the first element 101b and the second element 102s, the engagement between the third element 101g and the second element 102s, and the engagement between the outlet 101c and the supply port 102j are ensured. The flowable mixture 104 flowing out of the mold cavity 102i can be minimized or even prevented.

[0092] In operation 411, referring to FIG. 32, the first element 101b and the third element 101g are mixture After injection of 104, the protruding portion 101d of the first element 101b is displaced toward the second element 102s. In some embodiments, the protruding portion 101h of the third element 101g is received by the second slot 102e of the second element 102s while the protruding portion 101d of the first element 101b is received by the first slot 102e of the second element 102s. mixture After injection of 104, the protruding portion 101d of the first element 101b disengages from the protrusion 102f of the second element 102s, and the protruding portion 101h of the third element 101g disengages from the protrusion 102p of the second element 102s.

[0093] In some embodiments, after injection of the flowable mixture 104, the first element 101b and the third element 101g are displaced toward the second element 102s along arrow H as shown in FIG. 32 until the first element 101b disengages from the second element 102s. In some embodiments, the protruding portion 101d moves away from the protrusion 102f and the protruding portion 101h moves away from the protrusion 102p. In some embodiments, the first element 101b is moved toward the molding device 102 to disengage from the protrusion 102f and the third element 101g is moved toward the molding device 102 to disengage from the protrusion 102p. In some embodiments, the injector 101a remains stationary as the first element 101b and the third element 101g move downward as shown in FIG. 32. In some embodiments, separation between the protrusion 102f and the protruding portion 101d of the first element 101b is sensed by a first sensor 102l, and separation between the protrusion 102p and the protruding portion 101h of the third element 101g is sensed by a third sensor 102q.

[0094] In operation 412, referring to FIG. 33, the injector 101a is displaced away from the molding device 102. In some embodiments, the outlet 101c is mixture After injection of 104, the molding device 102 is retracted away from the molding device 102.

[0095] In some embodiments, after disengagement of the first element 101b and the third element 101g from the second element 102s, the injector 101a moves away from the molding device 102 along arrow J as shown in FIG. 33 until the outlet 101c of the injector 101a is no longer in contact with the molding device 102. In some embodiments, the separation of the injector 101a and the molding device 102 is sensed by a second sensor 102m. In some embodiments, the injector 101a, the first element 101b, and the third element 101g move away from the molding device 102 along arrow J. In some embodiments, the injector 101a, the first element 101b, and the third element 101g are moved consistently.

[0096] In operation 413, and referring to FIGS. 34 and 35, the molding apparatus 102: injection displaced away from unit 101, or injection The unit 101 is displaced away from the forming device 102 .

[0097] In some embodiments, after the injector 101a, the first element 101b, and the third element 101g are disengaged from the second element 102s, the molding device 102: injection Alternatively, after the injector 101a, the first element 101b and the third element 101g are disengaged from the second element 102s, injection The unit 101 is displaced away from the second element 102s. In some embodiments, the molding device 102 moves horizontally away from the injector 101a, the first element 101b, and the third element 101g along arrow K as shown in FIG. 34. Alternatively, the injector 101a, the first element 101b, and the third element 101g move horizontally away from the second element 102s and the molding device 102 along arrow M as shown in FIG. 34. FIG. 35 shows that the second element 102s is injection After being displaced away from unit 101, injection The unit 101 and the second element 102s are shown separated from each other.

[0098] In some embodiments, after disengaging the forming device 102 from the second element 102s, the forming device 102 is displaced away from the second element 102s. In some embodiments, the forming device 102 moves horizontally away from the second element 102s along arrow K, as shown in FIG. 35. In some embodiments, the forming device 102 may be displaced away from the second element 102s by rotating a carrier (not shown) disposed below the forming device 102, and another forming device (not shown) may be disposed below the second element 102s. Alternatively, after disengaging the second element 102s from the forming device 102, injectionThe unit 101, the forming device 102 and the second element 102s are separated from each other. In some embodiments, the forming device 102 moves horizontally away from the second element 102s. Alternatively, the second element 102s moves horizontally away from the forming device 102. Figure 36 shows that the second element 102s and the forming device 102 are separated from each other after the forming device 102 moves away from the second element 102s.

[0099] Also disclosed in the present disclosure is a third injection molding method 500. The third injection molding method 500 includes several operations, and the description and illustration are not to be considered as limiting the order of the operations. FIG. 37 is an embodiment of the third injection molding method 500. In some embodiments, the third injection molding method 500 includes several operations (501-506). In some embodiments, the third injection molding method 500 is performed by the first injection molding system 100 shown in FIGS. 1-5 or the second injection molding system 300 shown in FIGS. 19-23 described above.

[0100] In operation 501, an injection molding system is provided, the injection molding system comprising: injection A molding unit and a molding device, injection The unit is liquidity mixture and a molding device configured to eject a flowable material from the ejection port. mixture The mold cavity includes a supply port that is in communication with the mold cavity and correspondingly engageable with the outlet.

[0101] In operation 502, injection A support device is provided that is configured to facilitate engagement of the unit with the molding device, the support device comprising: injection The apparatus includes a first element connected to the unit and a second element disposed in the molding apparatus.

[0102] In operation 503, a protruding portion of a first element is aligned with a slot of a second element.

[0103] In operation 504, injection The unit is displaced to slide the protruding portion of the first element along the slot of the second element.

[0104] In operation 505, the outlet is displaced within the opening of the second element to engage the supply port as the protruding portion of the first element engages the slot of the second element.

[0105] In operation 506, the liquidity mixture is injected into the mold cavity.

[0106] One aspect of the present disclosure relates to an injection molding system, comprising: a supply unit configured to supply a flowable mixture of a polymeric material and a blowing agent; injection a dispensing unit including an outlet disposed distally from the supply unit and configured to discharge the flowable mixture. injection a molding apparatus configured to receive the flowable mixture from the discharge outlet, the molding apparatus including a mold cavity and a supply port in communication with the mold cavity and engageable with the discharge outlet; injection The molding device is disposed between the unit and the molding device. injection and a support device configured to facilitate engagement of the unit with the molding device. injection a first element connected to the unit and a second element disposed on the molding apparatus, the second element including a slot configured to receive a protruding portion of the first element, the protruding portion of the first element being slidable within and along the first slot of the second element.

[0107] In some embodiments, the second component is injectionThe second element further includes a protrusion for defining a first slot, the first slot and the protrusion being laterally elongated. In some embodiments, the protruding portion of the first element is engageable with the protrusion and slidable within the slot. In some embodiments, the second element further includes a groove configured to receive the outlet, the groove being laterally elongated along the second element parallel to the first slot. In some embodiments, the outlet is slidable within the groove. In some embodiments, the second element further includes an opening disposed within the groove. In some embodiments, a first sensor is disposed within the first slot and configured to sense contact between the protruding portion and the first slot. In some embodiments, a second sensor is disposed within the groove and configured to sense contact between the outlet and the groove. In some embodiments, a height of the first slot is greater than a thickness of the protruding portion of the first element. In some embodiments, the support device comprises: injection In some embodiments, the support device further comprises a third element connected to the unit, the first slot being configured to receive the first element and the third element. injection The second element further includes a third element connected to the unit, the second element further including a second slot configured to receive the third element.

[0108] An aspect of the present disclosure relates to an injection molding method, the method comprising the steps of providing an injection molding system, the injection molding system comprising: injection a molding unit and a molding device, injection The unit is liquidity mixture and a discharge port configured to discharge the fluid from the discharge port. mixture a mold cavity configured to receive the nozzle, the mold cavity including a supply port in communication with the mold cavity and correspondingly engageable with the outlet; injection providing a support device configured to facilitate engagement of the unit with the molding device, the support device comprising: injectiona first element connected to the unit and a second element disposed on the molding device; aligning a protruding portion of the first element with a slot of the second element; injection displacing the unit to slide the protruding portion of the first element along the slot of the second element; displacing the outlet within the opening of the second element to engage the outlet with the supply port when the protruding portion of the first element engages the slot of the second element; mixture into the mold cavity.

[0109] In some embodiments, the method further includes aligning the spout with a groove configured to receive the spout, the groove elongating laterally along the second element and parallel to the slot, and sliding the spout into the groove. In some embodiments, the alignment of the protruding portion of the first element with the slot of the second element and the alignment of the spout with the groove are performed simultaneously. In some embodiments, the method further includes extending the spout toward a molding apparatus and engaging the spout with a feed port, and sliding the spout into the groove. mixture and retracting the outlet from the molding device after injection of the fluid. In some embodiments, the method further includes moving the protruding portion of the first element into abutment against the protrusion of the second element while the protruding portion of the first element is received by the slot of the second element; mixture and disengaging the protruding portion of the first element from the slot of the second element after injection of the flowable material, the slot being defined by a protrusion. In some embodiments, the first element is moved away from the molding apparatus to abut against the protrusion and toward the molding apparatus to disengage from the protrusion. In some embodiments, the method includes disengaging the flowable material while the protruding portion of the first element is received by the slot of the second element. mixture moving the protruding portion of the first element toward a molding device after injection of injectionThe unit further comprises remaining stationary as the support device moves toward the molding device. mixture During injection, the protruding portion of the first element abuts the protrusion of the second element, and the outlet is communicable with the supply port.

[0110] The foregoing has outlined features of several embodiments so that those skilled in the art may better understand aspects of the present disclosure. It should be appreciated that those skilled in the art may readily use this disclosure 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. It should also be appreciated by those skilled in the art that such equivalent structures do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations of the present disclosure may be made without departing from the spirit and scope of the present disclosure.

[0111] Moreover, the scope of the present application is not limited to the particular embodiments of the processes, machines, manufacture, compositions of matter, means, methods, and steps described herein. As one skilled in the art will readily appreciate from this disclosure, any 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 result as the corresponding embodiments described herein may 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.

Claims

1. 1. An injection molding system comprising: a supply unit configured to supply a flowable mixture of the polymeric material and the blowing agent; an injection unit connected to the supply unit, the injection unit being disposed at a position remote from the supply unit and including an outlet configured to eject the flowable mixture provided by the supply unit; a molding apparatus configured to receive the flowable mixture from the discharge opening, A mold cavity; a supply port in communication with the mold cavity and engageable with the outlet; A molding device comprising: a support device configured to engage the injection unit with the molding device; Equipped with an injection molding system, wherein the support device includes a first element connected to the injection unit and a second element disposed on the molding apparatus, the second element including a first slot configured to receive a protruding portion of the first element, the protruding portion of the first element being slidable within and along the first slot of the second element, and the second element further including a groove configured to receive the discharge port, the groove extending along the first slot.

2. The injection molding system of claim 1 , wherein the second element includes an opening configured to receive the outlet of the injection unit.

3. The injection molding system of claim 1 , wherein the second element further includes a protrusion defining the first slot, the protrusion extending along the first slot.

4. The injection molding system of claim 1 , wherein the spout is slidable within and along the groove.

5. The injection molding system of claim 1 , wherein the second element further comprises an opening disposed within the groove.

6. 2. The injection molding system of claim 1, wherein the support device further includes a third element connected to the injection unit, and the first slot is configured to receive the first element and the third element.

7. 2. The injection molding system of claim 1, wherein the support device further includes a third element connected to the injection unit, the second element further including a second slot configured to receive the third element.

8. 1. An injection molding method comprising the steps of: providing an injection molding system including an injection unit and a molding apparatus, the injection unit including an outlet configured to discharge a flowable mixture, the molding apparatus including a mold cavity and a feed port configured to receive the flowable mixture from the outlet, the feed port being in communication with the mold cavity and correspondingly engageable with the outlet; providing a support device configured to engage the injection unit with the molding apparatus, the support device including a first element connected to the injection unit and a second element disposed on the molding apparatus; aligning a protruding portion of the first element with a slot of the second element, the slot including a protrusion extending therealong; displacing the injection unit to slide the protruding portion of the first element along the slot of the second element; displacing the spout within an opening of the second element to engage the spout with the supply port when the protruding portion of the first element engages the slot of the second element; injecting the flowable mixture into the mold cavity; A method comprising:

9. aligning the spout with a groove configured to receive the spout, the groove elongated laterally along the second element and parallel to the slot; sliding the spout into the groove; The method of claim 8 further comprising:

10. moving the protruding portion of the first element into contact with the protrusion of the second element while the protruding portion of the first element is disposed by the slot of the second element; separating the protruding portion of the first element from the slot of the second element after injection of the flowable mixture; The method of claim 8 , further comprising:

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