Molding device, injection molding system, and molding method

Abstract

To provide a molding device, an injection molding system and a molding method.SOLUTION: There is provided a molding device that comprises: a first mold; a second mold; a mold cavity; and a position control mechanism attached to the first mold and the second mold. The first mold and the second mold are movable by the position control mechanism individually. There is also provided a molding method that comprises the steps of: providing a molding device having a first mold, a second mold and a third mold; engaging the first mold with the second mold to form a first mold cavity; injecting a first material into the first mold cavity to form a first layer; disengaging the first mold from the second mold by a position control mechanism; engaging the third mold with the second mold to form a second mold cavity; injecting a second material into the second mold cavity to form an article; and disengaging the third mold from the second mold by the position control mechanism.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 18 / 582,693, filed February 21, 2024, which claims priority to U.S. Provisional Patent Application No. 63 / 498,265, filed April 25, 2023, and U.S. Provisional Patent Application No. 63 / 585,970, filed September 28, 2023, all of which are incorporated herein by reference in their entireties.

[0002] Technical Field The present invention relates to a molding apparatus, an injection molding system, and a molding method, and more particularly to a molding apparatus, an injection molding system, and a molding method for forming a molded article having multiple portions with different physical or functional properties. [Background technology]

[0003] Foamed polymer materials have many advantages, such as high strength, light weight, impact resistance, and thermal insulation. Foamed molded products can be produced by injection molding or extrusion. For example, a polymeric material is melted and mixed with a blowing agent to form a mixture, and then the mixture is injected or extruded into a mold cavity under force or pressure, causing the mixture to foam in the cavity, and then cooled to form a foamed molded product.

[0004] However, there is a need to improve the properties of foam-molded articles, such as providing different properties in different portions of the foam-molded article produced by the injection molding system. Therefore, there is a need to improve the structure of the injection molding system and the method for producing the foam-molded article. Summary of the Invention [Problem to be solved by the invention]

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

[0006] According to one embodiment of the present disclosure, there is provided a molding apparatus including a first mold, a second mold, a first mold cavity defined by the first mold and the second mold when the first mold is positioned opposite the second mold, and a position control mechanism attached to the first mold and the second mold, wherein the first mold and the second mold are independently movable by the position control mechanism.

[0007] According to one embodiment of the present disclosure, there is provided an injection molding system including: a carrier having a plurality of molding stations; a molding apparatus disposed within one of the molding stations and including a position control mechanism and first, second, and third molds held by the position control mechanism; and a first injection station disposed adjacent to the carrier and configured to inject a first polymeric material into a first mold cavity of the molding apparatus defined by the first and second molds. The position control mechanism is configured to independently move the first, second, and third molds.

[0008] According to one embodiment of the present disclosure, there is provided a molding method comprising the steps of: providing a molding apparatus having a first mold, a second mold, and a third mold; engaging the first mold with the second mold to form a first mold cavity defined by the first mold and the second mold; and injecting a first polymeric material into the first mold cavity to form a first layer from the first polymeric material in the first mold cavity. The molding method further comprises the steps of: releasing the first mold from the second mold by a position control mechanism; engaging the third mold with the second mold to form a second mold cavity defined by the second mold and the third mold; injecting a second polymeric material into the second mold cavity over the first layer to form a molded article including the first layer and a second layer from the second polymeric material; and releasing the third mold from the second mold by the position control mechanism. [Brief explanation of the drawings]

[0009] Aspects of the present disclosure will be best understood from the following detailed description when taken in conjunction with the accompanying drawings, in which: It should be noted that, in accordance with standard industry practice, various features have not been drawn to scale. In fact, the dimensions of various features may be arbitrarily increased or decreased for clarity of illustration.

[0010] [Figure 1] FIG. 1 is a schematic perspective view of a molding apparatus according to some embodiments of the present disclosure. [Figure 2] FIG. 1 is a schematic perspective view of a molding apparatus according to some embodiments of the present disclosure. [Figure 3] FIG. 1 is a schematic top view of a portion of a molding apparatus according to some embodiments of the present disclosure. [Figure 4] 1 is a schematic cross-sectional view of a portion of a molding apparatus according to some embodiments of the present disclosure. [Figure 5] FIG. 1 is a schematic perspective view of a molding apparatus according to some embodiments of the present disclosure. [Figure 6] FIG. 1 is a schematic perspective view of a molding apparatus according to some embodiments of the present disclosure. [Figure 7] FIG. 1 is a schematic perspective view of a molding apparatus according to some embodiments of the present disclosure. [Figure 8] FIG. 1 is a schematic perspective view of a molding apparatus according to some embodiments of the present disclosure. [Figure 9] 1 is a schematic cross-sectional view of a portion of a molding apparatus according to some embodiments of the present disclosure. [Figure 10] 1 is a schematic cross-sectional view of a portion of a molding apparatus according to some embodiments of the present disclosure. [Figure 11] FIG. 1 is a schematic top view of an injection molding system according to some embodiments of the present disclosure. [Figure 12] FIG. 1 is a schematic perspective view of an injection molding system according to some embodiments of the present disclosure. [Figure 13] 1 is a flowchart illustrating a molding method according to some embodiments of the present disclosure. [Figure 14] 1 is a flowchart illustrating a molding method according to some embodiments of the present disclosure. [Figure 15] FIG. 1 is a schematic perspective view of a portion of an injection molding system used in a method for manufacturing a molded article according to some embodiments of the present disclosure. [Figure 16] FIG. 1 is a schematic perspective view of a portion of an injection molding system used in a method for manufacturing a molded article according to some embodiments of the present disclosure. [Figure 17] 1A-1D are schematic cross-sectional views illustrating exemplary steps of a molding method according to an embodiment of the present disclosure. [Figure 18] FIG. 1 is a schematic perspective view of a portion of an injection molding system used in a method for manufacturing a molded article according to some embodiments of the present disclosure. [Figure 19] FIG. 1 is a schematic perspective view of a portion of an injection molding system used in a method for manufacturing a molded article according to some embodiments of the present disclosure. [Figure 20] FIG. 1 is a schematic perspective view of a portion of an injection molding system used in a method for manufacturing a molded article according to some embodiments of the present disclosure. [Figure 21] 1A-1D are schematic cross-sectional views illustrating exemplary steps of a molding method according to an embodiment of the present disclosure. [Figure 22] 1A-1D are schematic cross-sectional views illustrating exemplary steps of a molding method according to an embodiment of the present disclosure. [Figure 23] FIG. 1 is a schematic perspective view of a portion of an injection molding system used in a method for manufacturing a molded article according to some embodiments of the present disclosure. [Figure 24] FIG. 1 is a schematic perspective view of a portion of an injection molding system used in a method for manufacturing a molded article according to some embodiments of the present disclosure. [Figure 25] 1 is a schematic perspective view of a molded article manufactured by a molded article manufacturing method according to some embodiments of the present disclosure. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0011] The following disclosure provides many different embodiments or examples for implementing different features of the provided subject matter. Below, specific examples of components and arrangements are described to simplify the disclosure. It should be understood that these are merely examples and are not intended to be limiting. For example, in the following description, a reference to forming a first feature above or on a second feature may include an embodiment in which the first and second features are formed in direct contact with each other, or an embodiment in which an additional feature is formed between the first and second features such that the first and second features are not in direct contact with each other. Additionally, the disclosure may repeat reference numerals and / or letters in various examples. This repetition is for the purposes of brevity and clarity and does not, in itself, indicate a relationship between the various embodiments and / or configurations described.

[0012] Additionally, spatially relative terms such as "below," "lower," "bottom," "upper," "top," and the like may be used herein for ease of description to describe the relationship of one element or feature to another element(s) or feature(s), as shown in the drawings. Spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the drawings. The device may be oriented in other directions (rotated 90 degrees or at other orientations), and the spatially relative descriptors used herein may likewise be interpreted accordingly.

[0013] 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 some 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 operating examples / examples, or unless otherwise specified, all numerical ranges, amounts, values, and percentages relating to amounts of materials, times, temperatures, operating conditions, ratios of amounts, and the like, disclosed herein should be understood to be modified in all instances by the term "about." Accordingly, the numerical parameters set forth in the present disclosure and the appended claims are approximations that can be varied, if necessary, unless otherwise indicated. 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. Unless otherwise stated, all ranges disclosed herein are inclusive of the endpoints.

[0014] FIG. 1 is a schematic perspective view of a molding apparatus 100 in a closed configuration, and FIG. 2 is a schematic perspective view of the molding apparatus 100 in an open configuration, according to some embodiments of the present disclosure.

[0015] In some embodiments, the molding apparatus 100 includes a first mold 11a, a second mold 14, a first mold cavity 19a, and a position control mechanism 20. The first mold 11a functions as an upper mold, and the second mold 14 includes a lower mold 13 and an outer intermediate mold 15 disposed between the first mold 11a and the lower mold 13. When the first mold 11a is disposed opposite the second mold 14, the first mold cavity 19a for forming a molded product (not shown) is defined by the first mold 11a and the second mold 14. The position control mechanism 20 is attached to the first mold 11a and the second mold 14, and the first mold 11a and the second mold 14 can be moved independently by the position control mechanism.

[0016] In some embodiments, the upper mold 11, the lower mold 13, and the outer intermediate mold 15 define a first mold cavity 19a. In some embodiments, the first mold 11a corresponds to the second mold 14 in some configurations, such as size, shape, etc. The first mold 11a is placed on and engageable with the outer intermediate mold 15. In some embodiments, providing the molding apparatus 100 includes transporting the outer intermediate mold 15 toward the lower mold 13 and then placing the first mold 11a on the outer intermediate mold 15. In some embodiments, the first mold 11a is aligned with the lower mold 13. In some embodiments, as shown in FIG. 2, the molding apparatus 100 is in an open configuration. In some embodiments, the first mold 11a is placed on the outer intermediate mold 15 and is movable and engageable with respect to the outer intermediate mold 15, and the outer intermediate mold 15 is placed on the lower mold 13 and is movable and engageable with respect to the lower mold 13.

[0017] FIG. 3 shows a schematic top view of a portion of molding apparatus 100 in a closed configuration. FIG. 4 shows a cross-sectional view of a portion of molding apparatus 100 taken along line IV-IV′ in FIG. 3. In some embodiments, outer intermediate mold 15 of second mold 14 includes first and second portions 151 and 152 that are adjacent and engageable with each other. In some embodiments, first and second portions 151 and 152 are movable and detachable relative to each other. First and second portions 151 and 152 are movable toward or away from each other. In some embodiments, extensions 151 a and 152 a of first and second portions 151 and 152 surround bottom mold 13. Bottom mold 13 is stationary relative to first and second portions 151 and 152. In some embodiments, first and second portions 151 and 152 are attached to and engage with each other to seal first mold cavity 19 a when molding apparatus 100 is in the closed configuration. In some embodiments, first portion 151 and second portion 152 are separated from one another when molding apparatus 100 is in the open configuration (shown in FIG. 2 ), allowing a molded article (not shown) formed in first mold cavity 19 a to be easily removed from first mold cavity 19 a. In some embodiments, first portion 151 is separated from second portion 152 to expand first mold cavity 19 a. In some embodiments, first mold cavity 19 a is expanded when molding apparatus 100 is in the open configuration.

[0018] In some embodiments, as shown again in FIGS. 1 and 2, the first mold 11a is rotatable about a first axis C1 by a hinge 24 of the position control mechanism 20. In some embodiments, the first mold 11a can be tilted by rotating about the first axis C1. In some embodiments, when the first mold 11a is tilted (as shown in FIG. 2), a first angle σ1 exists between the bottom surface of the first mold 11a and the top surface 131 of the lower mold 13. In some embodiments, the first angle σ1 is in the range of 0 to 90 degrees. In some embodiments, the first angle σ1 is in the range of 10 to 80 degrees. In some embodiments, the first mold 11a is rotatable about the first axis C1 along a first direction R1. The first direction R1 is clockwise or counterclockwise.

[0019] In some embodiments, the second mold 14 is linearly movable along rails 25 of the position control mechanism 20. In some embodiments, the outer intermediate mold 15 and the lower mold 13 are disposed on a platform 23 and are linearly movable along rails 25 of the position control mechanism 20, so that the position control mechanism 20 can control the first distance D1 between the first mold 11 a and the second mold 14. In some embodiments, when the molding apparatus 100 is in the closed configuration, the platform 23 can press the second mold 14 toward the first mold 11 a, for example, the outer intermediate mold 15 and the lower mold 13 toward the first mold 11 a.

[0020] Figures 5, 6, 7 and 8 are schematic perspective views of a molding apparatus 200 according to some embodiments of the present disclosure. Figure 9 is a schematic perspective view of a portion of a molding apparatus 200 according to some embodiments of the present disclosure. For ease of explanation, reference numerals having similar or identical functions and characteristics are repeated in different embodiments and figures.

[0021] In some embodiments, as shown in FIGS. 5, 6, 7, and 8, the molding apparatus 200 is similar to the molding apparatus 100 and further includes a third mold 11c attached to and movable by the position control mechanism 20. The third mold 11c is placed on and engageable with the outer intermediate mold 15. In some embodiments, providing the molding apparatus 200 includes transporting the outer intermediate mold 15 toward the lower mold 13 and then placing the first mold 11a or the third mold 11c on the outer intermediate mold 15. In some embodiments, the third mold 11c is alignable with the lower mold 13. The third mold 11c is rotatable about a first axis C1 by a hinge 24 of the position control mechanism 20 and about a second axis C2 perpendicular to the first axis C1 by a pivot 26 of the position control mechanism 20. The first mold 11a and the third mold 11c are both rotatable about the second axis C2. In some embodiments, the first mold 11a is rotatable about the second axis C2 by a pivot 26 of the position control mechanism 20.

[0022] In some embodiments, the molding apparatus 200 includes a first mold 11a, a second mold 14, a third mold 11c, a fourth mold 17a, a fifth mold 17b, and a position control mechanism 20. In some embodiments, the first mold 11a and the third mold 11c are attached to the position control mechanism 20, and the second mold 14, which includes the outer intermediate mold 15 and the lower mold 13, is placed on a platform 23 of the position control mechanism 20.

[0023] In some embodiments, molding apparatus 100 (shown in FIG. 2) and molding apparatus 200 each further include a fourth mold 17a attached to first mold 11a. In some embodiments, first mold cavity 19a is defined by first mold 11a, second mold 14, and fourth mold 17a when first mold 11a is positioned opposite second mold 14 and fourth mold 17a is surrounded by first mold cavity 19a. In some embodiments, fourth mold 17a includes a shoe last.

[0024] In some embodiments, the molding apparatus 200 further includes a fifth mold 17b attached to the third mold 11c. In some embodiments, the fifth mold 17b includes a shoe last. The position control mechanism 20 is configured to move the first mold 11a and the fourth mold 17a relative to the second mold 14, and is configured to move the third mold 11c and the fifth mold 17b relative to the second mold 14. The first mold 11a and the third mold 11c are attached so as to be movable relative to the second mold 14 by operation of the position control mechanism 20.

[0025] In some embodiments, the position control mechanism 20 drives or actuates the first mold 11a and the third mold 11c to move towards or away from the second mold 14. It can be seen that the maximum displacement of the first mold 11a and the outer intermediate mold 15 and the maximum displacement of the third mold 11c and the outer intermediate mold 15 are limited by the position control mechanism 20. In some embodiments, the first distance D1 between the first mold 11a and the second mold 14 is controlled by the position control mechanism 20.

[0026] In some embodiments, the position control mechanism 20 is configured to drive or actuate the first mold 11a to move upward so as to create a first distance D1 between the second mold 14 and the first mold 11a when the molding apparatus 200 is in the open configuration. In some embodiments, the position control mechanism 20 is configured to create relative movement between the first mold 11a and the second mold 14. As shown in FIG. 8 , the molding apparatus 200 is in the open configuration, and the first distance D1 reaches its maximum value. In some embodiments, the position control mechanism 20 is configured to drive or actuate the third mold 11c to move upward so as to create a gap (not shown) between the second mold 14 and the third mold 11c when the molding apparatus 200 is in the open configuration. In some embodiments, the position control mechanism 20 is configured to create relative movement between the third mold 11c and the second mold 14.

[0027] In some embodiments, the position control mechanism 20 is rotatable about the second axis C2 along the second direction R2, and the first mold 11a and the third mold 11c can be sequentially positioned above the second mold 14 as the position control mechanism 20 rotates about the second axis C2. The second direction R2 is clockwise or counterclockwise. In some embodiments, as shown in FIGS. 7 and 8, when the first mold 11a is positioned above the second mold 14, which includes the lower mold 13 and the outer intermediate mold 15, in a top view and is aligned with the second mold 14, the third mold 11c and the second mold 14 are laterally offset from each other in a top view. In some embodiments, when the third mold 11c is positioned above the second mold 14 in a top view and is aligned with the second mold 14, the first mold 11a and the second mold 14 are laterally offset from each other in a top view (not shown).

[0028] In some embodiments, the first mold 11a and the third mold 11c are rotatable along a first direction R1 around a first axis C1. In some embodiments, the third angle σ3 is fixed during rotation of the first mold 11a and the third mold 11c around the first axis C1. In some embodiments, the position control mechanism 20 is attached to the first end 11d of the first mold 11a and configured to tilt the first mold 11a relative to the second mold 14. In some embodiments, the position control mechanism 20 is configured to tilt the first mold 11a relative to the lower mold 13 and the outer intermediate mold 15 and to move the second end 11e of the first mold 11a higher than the first end 11d of the first mold 11a (as shown in FIGS. 5 and 6 ). The first mold 11a can be tilted by the position control mechanism 20 when a first distance D1 between the first mold 11a and the outer intermediate mold 15 is equal to or greater than zero. In some embodiments, before the fourth mold 17a is tilted, the bottom surface of the first mold 11a is parallel to the top surface of the outer intermediate mold 15. In some embodiments, the position control mechanism 20 is configured to generate a relative tilt between the fourth mold 17a and the outer intermediate mold 15. In some embodiments, when the first mold 11a and the fourth mold 17a are tilted (as shown in FIGS. 5 and 6), a first angle σ1 exists between the first mold 11a and the second mold 14. In some embodiments, the first angle σ1 is in the range of 0 to 90 degrees. In some embodiments, the first angle σ1 is in the range of 20 to 70 degrees. In some embodiments, the first angle σ1 is 45 degrees when the position control mechanism 20 rotates about the second axis C2.

[0029] In some embodiments, the position control mechanism 20 is attached to the first end 11f of the third mold 11c and is configured to tilt the third mold 11c relative to the second mold 14. In some embodiments, the position control mechanism 20 is configured to tilt the third mold 11c relative to the second mold 14 and move the second end 11g of the third mold 11c higher than the first end 11f of the third mold 11c. The third mold 11c can be tilted by the position control mechanism 20 when a gap (not shown) between the third mold 11c and the second mold 14 is zero or greater. In some embodiments, before the third mold 11c is tilted, the bottom surface of the third mold 11c is parallel to the top surface of the outer intermediate mold 15. In some embodiments, the position control mechanism 20 is configured to generate a relative tilt between the third mold 11c and the outer intermediate mold 15. In some embodiments, when the third mold 11c and the fifth mold 17b are tilted, a second angle σ2 exists between the third mold 11c and the second mold 14. In some embodiments, the second angle σ2 is in the range of 0 to 90 degrees. In some embodiments, the second angle σ2 is in the range of 20 to 70 degrees. In some embodiments, the second angle σ2 is 45 degrees when the position control mechanism 20 rotates about the second axis C2.

[0030] In some embodiments, as shown in Figures 5 and 6, the fourth mold 17a includes a first end 173 and a second end 174 opposite the first end 173, and the position control mechanism 20 is configured to tilt the fourth mold 17a relative to the second mold 14 and move the second end 174 of the fourth mold 17a higher than the first end 173 of the fourth mold 17a.

[0031] In some embodiments, when the first mold 11a and the third mold 11c are attached to the position control mechanism 20, a third angle σ3 exists between the first mold 11a and the third mold 11c. In some embodiments, the third angle σ3 is in the range of 0 to 180 degrees. In some embodiments, the third angle σ3 is in the range of 40 to 140 degrees. In some embodiments, the third angle σ3 is 90 degrees when the position control mechanism 20 rotates about the second axis C2. In some embodiments, the third angle σ3 is fixed during rotation of the first mold 11a and the third mold 11c about the second axis C2. In some embodiments, the third angle σ3 changes during rotation of the first mold 11a and the third mold 11c about the second axis C2. That is, at least one of the first mold 11a and the third mold 11c is rotatable about the first axis C1 during rotation of the first mold 11a and the third mold 11c about the second axis C2.

[0032] 9 and 10 are cross-sectional views of a portion of molding apparatus 200. In some embodiments, first mold 11a and third mold 11c are configured differently. In some embodiments, first mold 11a and third mold 11c are configured similarly. In some embodiments, as shown in FIG. 9, first mold cavity 19a is defined by first mold 11a, outer intermediate mold 15, fourth mold 17a, and lower mold 13 when molding apparatus 200 is in a first closed configuration, with first mold 11a positioned opposite second mold 14 and fourth mold 17a surrounded by first mold cavity 19a. In some embodiments, third mold 11c is offset substantially perpendicularly from first mold 11a when first mold 11a is positioned opposite second mold 14.

[0033] In some embodiments, the first supply port 12a extends through the first mold 11a. In some embodiments, the first mold 11a includes the first supply port 12a. The first supply port 12a has an opening 121a disposed in the first mold 11a. In some embodiments, the second mold 14 includes the first supply port 12a. In some embodiments, the outer intermediate mold 15 or the lower mold 13 includes the first supply port 12a. In some embodiments, the first supply port 12a can be in communication with the first mold cavity 19a when the molding apparatus 200 is in the first closed configuration as shown in FIG. 9.

[0034] Alternatively, in some embodiments, the first mold cavity 19a is accessible through multiple first supply ports 12a. For simplicity and clarity, two first supply ports 12a are shown, but it can be understood that any suitable number of first supply ports 12a may be configured in the first mold 11a. In some embodiments, instead of configuring the first supply ports 12a in the first mold 11a, the first supply ports 12a are disposed in the lower mold 13 or the outer intermediate mold 15 to access the first mold cavity 19a. In some embodiments, each first supply port 12a may be configured in the first mold 11a, the upper surface 131 of the lower mold 13, the inner wall 153 of the outer intermediate mold 15, or any other suitable location, provided that the first supply port 12a is capable of communicating with the first mold cavity 19a.

[0035] In some embodiments, the molding apparatus 200 further includes one or more pressure adjustment systems 16. In some embodiments, the pressure adjustment system 16 is attached to the second mold 14. In some embodiments, the pressure adjustment system 16 is attached to the lower mold 13 or the outer intermediate mold 15. In some embodiments, when the first mold 11a is positioned opposite the second mold 14, the pressure adjustment system 16, including the gas conduit 161 and the connection point 167, is connected to the first mold cavity 19a and the gas conduit 161. In some embodiments, multiple connection points 167 are arranged on the second mold 14 and connected to the first mold cavity 19a. In some embodiments, the connection points 167 are configured to allow fluid or gas to enter and exit the first mold cavity 19a. The position, shape, and number of the connection points 167 are not particularly limited and can be adjusted as needed. In some embodiments, each connection point 167 is a hole. In some embodiments, the connection points 167 are configured to supply or discharge gas.

[0036] In some embodiments, pressure regulation system 16 further includes a pressure detection unit (not shown) configured to detect the pressure within first mold cavity 19a. This pressure detection unit (not shown) is not limited to a specific type, as long as it can detect the pressure within first mold cavity 19a and provide pressure information after detecting the pressure. Pressure regulation system 16 adjusts the pressure within first mold cavity 19a by changing the conditions for gas flow into and out of first mold cavity 19a in response to the pressure information provided by the pressure detection unit (not shown), thereby adjusting the pressure within first mold cavity 19a so that the resulting composite has a desired predetermined shape and properties. In some embodiments, the pressure detection unit (not shown) is disposed within first mold cavity 19a.

[0037] In some embodiments, one end of the first gas conduit 161 is connected to the connection point 167, and the other end of the first gas conduit 161 is connected to a gas controller 163. In some embodiments, the gas controller 163 is configured to supply or discharge a fluid or gas, and can supply or discharge a suitable fluid or gas, such as air, an inert gas, or the like, as needed, although the present disclosure is not limited thereto.

[0038] 10, second mold cavity 19b is defined by third mold 11c, outer intermediate mold 15, lower mold 13, and fifth mold 17b when molding apparatus 200 is in the second closed configuration. In some embodiments, when third mold 11c is positioned opposite second mold 14, first mold 11a is offset substantially perpendicularly from third mold 11c.

[0039] In some embodiments, second supply port 12b extends through third mold 11c. In some embodiments, third mold 11c includes second supply port 12b. Second supply port 12b has opening 121b disposed in third mold 11c. In some embodiments, second mold 14 includes second supply port 12b. In some embodiments, second supply port 12b is communicable with second mold cavity 19b when third mold 11c is disposed opposite second mold 14, fifth mold 17b is surrounded by second mold cavity 19b, and molding apparatus 200 is in the second closed configuration as shown in FIG.

[0040] Alternatively, in some embodiments, the second mold cavity 19b is accessible through multiple second supply ports 12b. While two second supply ports 12b are shown for simplicity and clarity, it can be understood that any suitable number of second supply ports 12b may be configured in the third mold 11c. In some embodiments, instead of configuring the second supply ports 12b in the third mold 11c, the second supply ports 12b are located in the lower mold 13 or the outer intermediate mold 15 to access the second mold cavity 19b. In some embodiments, each second supply port 12b may be configured in the third mold 11c, the upper surface 131 of the lower mold 13, the inner wall 153 of the outer intermediate mold 15, or any other suitable location, so long as the second supply port 12b is capable of communicating with the second mold cavity 19b.

[0041] In some embodiments, when the third mold 11c is positioned opposite the second mold 14, a pressure regulation system 16 including a gas conduit 161 and connection points 167 is connected to the second mold cavity 19b and the gas conduit 161. In some embodiments, a plurality of connection points 167 are disposed on the second mold 14 and connected to the second mold cavity 19b. In some embodiments, the connection points 167 are configured to allow fluid or gas to enter and exit the second mold cavity 19b.

[0042] In some embodiments, pressure regulation system 16 further includes a pressure detection unit (not shown) configured to detect the pressure in second mold cavity 19b. This pressure detection unit (not shown) is not limited to a specific type, as long as it can detect the pressure in second mold cavity 19b and provide pressure information after detecting the pressure. Pressure regulation system 16 adjusts the pressure in second mold cavity 19b by changing the conditions for gas flow into and out of second mold cavity 19b in response to the pressure information provided by the pressure detection unit (not shown), thereby adjusting the pressure in second mold cavity 19b, so that the resulting composite has a desired predetermined shape and properties. In some embodiments, the pressure detection unit (not shown) is disposed in second mold cavity 19b.

[0043] Figure 11 is a top view of an injection molding system 300 according to some embodiments of the present disclosure. Figure 12 is a schematic perspective view of an injection molding system 300 according to some embodiments of the present disclosure.

[0044] 11 and 12, an injection molding system 300 includes a carrier 101 having a plurality of molding stations 400, each configured to carry a molding apparatus 100 or a molding apparatus 200. In some embodiments, the molding apparatus 200 shown in FIGS. 5 to 8 is disposed within one of the molding stations 400 and includes a position control mechanism 20, and a first mold 11a, a third mold 11c, and a second mold 14 held by the position control mechanism 20. The position control mechanism 20 is configured to individually move the first mold 11a, the second mold 14, and the third mold 11c.

[0045] The first injection station 21 is disposed adjacent to the carrier 101 and is configured to inject a first polymeric material into a first mold cavity 19a of the molding apparatus 200 defined by the first mold 11a and the second mold 14 including the outer intermediate mold 15 and the lower mold 13. In some embodiments, the second injection station 22 is disposed adjacent to the carrier 101 and is separated from the first injection station 21 and is configured to inject a second polymeric material into a second mold cavity 19b of the molding apparatus 200 defined by the second mold 14 and the third mold 11c.

[0046] In some embodiments, the molding stations 400 are disposed on a carrier 101, and multiple molding devices 200 are disposed on the carrier 101, each disposed within a molding station 400. In some embodiments, the first injection station 21 and the second injection station 22 are disposed adjacent to the carrier 101 and above two of the molding stations 400.

[0047] In some embodiments, the first injection station 21 includes a first extrusion system (not shown) and a first discharge passage (not shown) disposed above one of the molding stations 400. In some embodiments, the first polymeric material produced by the first injection station 21 is a mixture of the first polymeric material and a first foaming agent. In some embodiments, the first discharge passage is communicable with the first extrusion system and includes a first outlet disposed away from the first extrusion system and configured to discharge the first polymeric material into the molding apparatus 200 through the first supply port 12a. In some embodiments, the molding apparatus 200 is configured to receive the first polymeric material from the first outlet of the first discharge passage. In some embodiments, the first supply port 12a is communicable with the first mold cavity 19a and is engageable with the first outlet. In some embodiments, the first polymeric material is non-foaming or micro-foaming.

[0048] In some embodiments, the second injection station 22 includes a second extrusion system (not shown) and a second discharge passage (not shown) disposed above one of the molding stations 400. In some embodiments, the second polymeric material produced by the second injection station 22 is a mixture of the second polymeric material and a second blowing agent. In some embodiments, the second discharge passage is communicable with the second extrusion system and includes a second outlet disposed away from the second extrusion system and configured to discharge the second polymeric material into the molding apparatus 200 through the second supply port 12b. In some embodiments, the molding apparatus 200 is configured to receive the second polymeric material from the second outlet of the second discharge passage. In some embodiments, the second supply port 12b is communicable with the second mold cavity 19b and is engageable with the second outlet. In some embodiments, the second polymeric material is non-foaming or micro-foaming.

[0049] In some embodiments, the carrier 101 is toric. In some embodiments, the carrier 101 is rotatable along a third direction R3 about a third center C3. In some embodiments, the carrier 101 is rotatable clockwise or counterclockwise. In some embodiments, the carrier 101 rotates at predetermined intervals.

[0050] In some embodiments, the first injection station 21 and the second injection station 22 are separated from each other. In some embodiments, there is a predetermined distance between the first injection station 21 and the second injection station 22. In some embodiments, the first injection station 21 and the second injection station 22 are automatically operated and controlled. In some embodiments, the first injection station 21 and the second injection station 22 can communicate with each other via any suitable communication protocol, such as a programmable logic controller (PLC) protocol.

[0051] The present disclosure also discloses a molding method M10. Figure 13 is a flowchart illustrating the molding method M10 according to some embodiments of the present disclosure. The method M10 includes the steps of: providing a molding apparatus (O101) having a first mold, a second mold, and a third mold; engaging the first mold and the second mold to form a first mold cavity defined by the first mold and the second mold; injecting a first polymeric material into the first mold cavity to form a first layer from the first polymeric material in the first mold cavity (O103); and separating the first mold from the second mold by a position control mechanism. In some embodiments, method M10 includes using molding apparatus 200. The method further includes the steps of: disengaging the third mold from the second mold (O104); engaging the third mold with the second mold to form a second mold cavity defined by the second mold, the third mold, and the fourth mold (O105); injecting a second polymeric material into the second mold cavity over the first layer to form a molded article comprising the first layer and a second layer from the second polymeric material (O106); and disengaging the third mold from the second mold with a position control mechanism (O107). In some embodiments, method M10 includes using molding apparatus 200.

[0052] The present disclosure also discloses a molding method M20. Figure 14 is a flowchart illustrating molding method M20 according to some embodiments of the present disclosure. Method M20 includes the steps of: providing a molding apparatus having a first mold, a second mold, and a third mold (O201); engaging the first mold and the second mold to form a first mold cavity defined by the first mold and the second mold (O202); injecting a first polymeric material into the first mold cavity to form a first layer from the first polymeric material in the first mold cavity (O203); injecting a second polymeric material into the first mold cavity to form a second layer from the second polymeric material in the first mold cavity (O204); and separating the first mold from the second mold by a position control mechanism (O205). 5), placing the part in a fifth mold attached to the third mold (O206), engaging the third mold with the second mold to form a second mold cavity defined by the second mold, the third mold, and the fifth mold (O207), injecting a third polymeric material into the second mold cavity over the first and second layers to form a molded article comprising the first layer, the second layer, and a third layer from the third polymeric material (O208), detaching the third mold from the second mold by a position control mechanism (O209), and obtaining the molded article comprising the first layer, the second layer, and the part from the molding apparatus (O210).

[0053] In some embodiments, molding method M20 includes using molding apparatus 200. The method includes many steps, and the description and illustrations are not to be considered as limiting the sequence of steps. Figures 15-25 are schematic perspective views of one or more steps of molding method M20 according to some embodiments of the present disclosure.

[0054] In some embodiments, an injection molding system 300 for step O201 of method M20 according to some embodiments of the present disclosure is shown in FIGS. 11 and 12. In some embodiments, molding method M20 includes step O201 including providing a molding apparatus 200 having a first mold 11a, a second mold 14, a third mold 11c, and a position control mechanism 20. In some embodiments, second mold 14 includes a lower mold 13 and an outer intermediate mold 15, and a fourth mold 17a is attached to first mold 11a. In some embodiments, molding apparatus 200 is provided or received as shown in FIGS. 5, 6, 7, and 8. In some embodiments, molding apparatus 200 is configured to form a molded article. In some embodiments, molding apparatus 200 is provided or received including a pressure regulation system 16 having connection points 167, gas conduits 161, and a pressure detection unit (not shown).

[0055] 15, in step O201, molding apparatus 200 is in an open configuration. In some embodiments, in step O201, first mold 11a and second mold 14 are separated from each other. In some embodiments, first mold 11a is moved vertically to a first position above second mold 14. In the first position, first mold 11a is aligned with second mold 14 of molding apparatus 200. In some embodiments, a first distance D1 between first mold 11a and second mold 14 is greater than zero.

[0056] In some embodiments, the position control mechanism 20 moves the first mold 11a toward or away from the second mold 14. In some embodiments, the position control mechanism 20 moves the second mold 14, which is disposed on the platform 23, toward or away from the first mold 11a. In some embodiments, the position control mechanism 20 holds the third mold 11c offset from the second mold 14. In some embodiments, the molding method M20 includes a step of hingedly rotating the first mold 11a toward the second mold 14 or linearly moving the second mold 14 toward the first mold 11a to engage the first mold 11a and the second mold 14. In some embodiments, the molding method M20 includes a step of pivotally rotating the first mold 11a and the third mold 11c to position the first mold 11a or the third mold 11c above the second mold 14.

[0057] 16, a carrier 101 is provided having a plurality of molding stations 400, each of which includes a molding apparatus 200. In some embodiments, the molding apparatus 200 is disposed within one of the molding stations 400 of the carrier 101. In some embodiments, a first injection station 21 configured to inject a first polymeric material into the molding apparatus 200 and a second injection station 22 configured to inject a second polymeric material into the molding apparatus 200 are provided and disposed adjacent to the carrier 101.

[0058] In some embodiments, molding method M20 includes step O202, which includes engaging a first mold 11a and a second mold 14 to form a first mold cavity 19a defined by the first mold 11a and the second mold 14.

[0059] In some embodiments, the position control mechanism 20 either hinges the first mold 11a about the first axis C1 along a first direction R1 toward the second mold 14, or linearly moves the second mold 14 toward the first mold 11a to engage the first mold 11a and the second mold 14. The first direction R1 is clockwise or counterclockwise.

[0060] In some embodiments, the position control mechanism 20 pivots the first mold 11a and the third mold 11c about the second axis C2 along the second direction R2 to position the first mold 11a or the third mold 11c above the second mold 14. The second direction R2 is clockwise or counterclockwise. In some embodiments, the pivot rotation and the hinge rotation are performed separately in sequence.

[0061] 17, the first mold 11a, the lower mold 13, the outer intermediate mold 15, and the fourth mold 17a of the molding apparatus 200 are in a first closed configuration, and the third mold 11c is held by the position control mechanism 20. In some embodiments, the third mold 11c and the second mold 14 are laterally offset in a top view.

[0062] In some embodiments, the second angle σ2 between the third mold 11c and the second mold 14 is in the range of 0 to 90 degrees. In some embodiments, the second angle σ2 is 90 degrees when the molding apparatus 200 is in the first closed configuration. In some embodiments, the third angle σ3 between the first mold 11a and the third mold 11c is in the range of 0 to 180 degrees. In some embodiments, the third angle σ3 is 90 degrees when the molding apparatus 200 is in the first closed configuration.

[0063] In some embodiments, molding method M20 includes step O203, which includes injecting a first polymeric material into first mold cavity 19a to form a first layer M1 from the first polymeric material in first mold cavity 19a.

[0064] Continuing with FIG. 17 , a first polymeric material is injected into first mold cavity 19a through one of first inlets 12a. In some embodiments, the first polymeric material comprises thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or any other suitable material. In some embodiments, the first polymeric material comprises a physical blowing agent, such as a supercritical fluid. In some embodiments, the physical blowing agent is gaseous nitrogen, carbon dioxide, or the like. In some embodiments, the first polymeric material is foaming, non-foaming, or micro-foaming. In some embodiments, the first polymeric material comprises a first dye. In some embodiments, the first polymeric material forms a first layer M1 in first mold cavity 19a. In some embodiments, the first layer M1 is formed between first mold 11a and lower mold 13. In some embodiments, the first layer M1 is formed between fourth mold 17a and lower mold 13.

[0065] In some embodiments, the pressure within first mold cavity 19a is sensed prior to injection of the first polymeric material. In some embodiments, a first gas (not shown) is injected into first mold cavity 19a through connection point 167 until first mold cavity 19a is sensed to have a first predetermined pressure prior to injection of the first polymeric material.

[0066] In some embodiments, the method further includes detecting a pressure in the first mold cavity 19a and filling the first mold cavity 19a with a first polymeric material at a first predetermined pressure from a first supply port 12a. In some embodiments, the method further includes discharging a portion of a first gas (not shown) from the first mold cavity 19a through a connection point 167.

[0067] In some embodiments, a first force is applied to the second mold 14 toward the first mold 11a when the molding apparatus 200 is in the first closed configuration to facilitate engagement between the first mold 11a and the second mold 14. In some embodiments, the first force is applied to the second mold 14 prior to the injection of the first gas into the first mold cavity 19a or prior to the injection of the first polymeric material into the first mold cavity 19a. In some embodiments, the first force is applied to the second mold 14 during the injection of the first gas into the first mold cavity 19a or during the injection of the first polymeric material into the first mold cavity 19a. In some embodiments, the platform 23 provides the first force to the second mold 14.

[0068] In some embodiments, molding apparatus 200 is disposed on carrier 101, a first extrusion system (not shown) and molding apparatus 200 are disposed in first injection station 21, and a first polymeric material is injected from the first extrusion system into molding apparatus 200 at first injection station 21. In some embodiments, the first polymeric material is injected into molding apparatus 200 through a first mold 11a.

[0069] In some embodiments, at the first injection station 21, the first mold 11a is attached to the outer intermediate mold 15, and the third mold 11c, held by the position control mechanism 20, is positioned away from the outer intermediate mold 15. In some embodiments, the first mold 11a is positioned below the first extrusion system. In some embodiments, the third mold 11c is positioned above the position control mechanism 20.

[0070] In some embodiments, molding method M20 includes step O204, which includes injecting a second polymeric material into first mold cavity 19a to form a second layer M2 from the second polymeric material within first mold cavity 19a.

[0071] Continuing with FIG. 17 , a second polymeric material is injected into first mold cavity 19a through one of first inlets 12a. In some embodiments, the first polymeric material and the second polymeric material are injected into first mold cavity 19a. In some embodiments, the second polymeric material comprises thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or any other suitable material. In some embodiments, the second polymeric material comprises a physical blowing agent, such as a supercritical fluid. In some embodiments, the physical blowing agent is gaseous nitrogen, carbon dioxide, or the like. In some embodiments, the second polymeric material is foamable, non-foamable, or micro-foamable. In some embodiments, the second polymeric material comprises a second dye. The second dye may be similar to or different from the first dye. In some embodiments, the first polymeric material and the second polymeric material are non-foamable. In some embodiments, the first polymeric material and the second polymeric material are micro-foamable. In some embodiments, the composition of the second polymeric material may be similar to or different from the composition of the first polymeric material. In some embodiments, the first polymeric material and the second polymeric material have different physical properties, such as different densities.

[0072] In some embodiments, the second polymeric material forms a second layer M2 adjacent to the first layer M1. In some embodiments, the second layer M2 is connected to the first layer M1. In some embodiments, the second layer M2 is spaced apart from the first layer M1. In some embodiments, the second layer M2 is formed between the first mold 11a and the lower mold 13. In some embodiments, the second layer M2 is formed between the fourth mold 17a and the lower mold 13. In some embodiments, the first polymeric material and the second polymeric material are injected simultaneously. In some embodiments, the first layer M1 and the second layer M2 are formed simultaneously. In some embodiments, the first layer M1 and the second layer M2 have different physical properties, such as different densities. The first layer M1 and the second layer M2 may be the same color or different colors.

[0073] In some embodiments, the pressure within first mold cavity 19a is sensed prior to injection of the second polymeric material. In some embodiments, a second gas (not shown) is injected into first mold cavity 19a through connection point 167 until first mold cavity 19a is sensed to have a second predetermined pressure prior to injection of the second polymeric material.

[0074] In some embodiments, molding method M20 further includes detecting the pressure in first mold cavity 19a and filling first mold cavity 19a with a second polymeric material at a second predetermined pressure through first supply port 12a. In some embodiments, molding method M20 further includes discharging a portion of a second gas (not shown) from first mold cavity 19a through connection point 167. In some embodiments, the second predetermined pressure and the first predetermined pressure are the same.

[0075] In some embodiments, the second force is applied to the second mold 14 before the injection of the second gas into the first mold cavity 19a or before the injection of the second polymeric material into the first mold cavity 19a. In some embodiments, the second force is applied to the second mold 14 during the injection of the second gas into the first mold cavity 19a or during the injection of the second polymeric material into the first mold cavity 19a.

[0076] In some embodiments, molding apparatus 200 is disposed on carrier 101, a first extrusion system (not shown) and molding apparatus 200 are disposed in first injection station 21, and the second polymeric material is injected from the first extrusion system into molding apparatus 200 at first injection station 21. In some embodiments, the second polymeric material is injected into molding apparatus 200 through first mold 11a.

[0077] In some embodiments, after the first layer M1 and the second layer M2 are formed, a third mold cavity 19c is formed in the molding apparatus 200. In some embodiments, the volume of the third cavity 19c is smaller than the volume of the first cavity 19a. In some embodiments, the volume of the third cavity 19c is greater than zero.

[0078] In some embodiments, the molding method M20 includes a step O205 that includes separating the first mold 11a from the second mold 14 by the position control mechanism 20.

[0079] 18, after the first layer M1 and the second layer M2 are formed in the molding apparatus 200, the first mold 11a moves away from the second mold 14, the first layer M1, and the second layer M2. In some embodiments, the second mold 14, the first layer M1, and the second layer M2 are transported together as the carrier 101 rotates.

[0080] In some embodiments, after the first layer M1 and the second layer M2 are formed, the molding apparatus 200 is opened. In some embodiments, the application of the second force to the molding apparatus 200 is stopped before the first mold 11a is separated from the second mold 14. In some embodiments, after the first layer M1 and the second layer M2 are formed, the first mold 11a is moved away from the second mold 14, exposing the first layer M1 and the second layer M2.

[0081] In some embodiments, during movement, the molding apparatus 200 is in an open configuration, as shown in FIG. 18 . In some embodiments, during movement, the first mold 11a and the second mold 14 are separated from each other. In some embodiments, the first mold 11a moves vertically toward a first position above the second mold 14. At the first position, the first mold 11a is aligned with the second mold 14 of the molding apparatus 200. In some embodiments, a first distance D1 between the first mold 11a and the second mold 14 is greater than zero. In some embodiments, the position control mechanism 20 moves the first mold 11a away from the second mold 14. In some embodiments, the position control mechanism 20 moves the platform 23 along the rail 25, thereby moving the second mold 14, which is disposed on the platform 23, away from the first mold 11a.

[0082] 16 , after the first layer M1 and the second layer M2 are formed, the molding apparatus 200 moves from the first injection station 21 toward the second injection station 22. In some embodiments, the carrier 101 rotates along a third direction R3 about a third center C3 to move the molding apparatus 200 from the first injection station 21 toward the second injection station 22.

[0083] 19, after the first mold 11a and the second mold 14 are separated from each other, the position control mechanism 20 tilts the first mold 11a and the third mold 11c. In some embodiments, the first mold 11a and the third mold 11c are rotatable along a first direction R1 around a first axis C1.

[0084] In some embodiments, the first angle σ1 exists between the bottom surface of the first mold 11a and the top surface of the second mold 14, the second angle σ2 exists between the bottom surface of the third mold 11c and the top surface of the second mold 14, and the third angle σ3 exists between the first mold 11a and the third mold 11c. In some embodiments, the first angle σ1 and the second angle σ2 are each 45 degrees, and the third angle σ3 is 90 degrees.

[0085] In some embodiments, the first mold 11a and the third mold 11c are tilted by a position control mechanism 20, which rotates around a second axis C2 to move the third mold 11c toward the second mold 14 and move the first mold 11a away from the second mold 14, as shown in FIG. 19.

[0086] In some embodiments, molding method M20 includes a step O206 that includes placing part 175 in fifth mold 17b attached to third mold 11c.

[0087] In some embodiments, component 175 is attached to fifth mold 17b. In some embodiments, component 175 is placed in fifth mold 17b. In some embodiments, component 175 is conformal to fifth mold 17b. In some embodiments, component 175 comprises a third polymeric material. In some embodiments, component 175 is permeable to a gas or fluid (such as air, supercritical fluid, inert gas, nitrogen, carbon dioxide, etc.). In some embodiments, component 175 comprises a fabric. In some embodiments, component 175 is an insole, a footwear upper, or any other suitable component of footwear.

[0088] In some embodiments, a barrier layer (not shown) is disposed between part 175 and fifth mold 17b. In some embodiments, the barrier layer (not shown) is attached to the inner surface of part 175 before placing part 175 on fifth mold 17b. In some embodiments, the inner surface of part 175 and the barrier layer (not shown) are disposed on fifth mold 17b after placing part 175 on fifth mold 17b. In some embodiments, the barrier layer (not shown) is conformal to part 175. In some embodiments, the barrier layer (not shown) is a TPU film.

[0089] 20 , after the position control mechanism 20 rotates about the second axis C2 to move the third mold 11c toward the second mold 14, the first mold 11a and the third mold 11c rotate about the first axis C1 along the first direction R1 until the third mold 11c is positioned at a second position above the second mold 14 and the first mold 11a is positioned above the position control mechanism 20. At the second position, the third mold 11c is aligned with the second mold 14 of the molding apparatus 200. In some embodiments, the second distance D2 between the third mold 11c and the second mold 14 is greater than 0. In some embodiments, the second angle σ2 and the third angle σ3 are each 90 degrees.

[0090] In some embodiments, the position control mechanism 20 moves the third mold 11c toward the second mold 14. In some embodiments, the position control mechanism 20 moves the second mold 14, which is disposed on the platform 23, toward the third mold 11c.

[0091] In some embodiments, the molding apparatus 200, including the lower mold 13, the outer intermediate mold 15, the first layer M1, and the second layer M2, is transferred to and positioned within the second injection station 22. In some embodiments, the second extrusion system (not shown) and the molding apparatus 200 are positioned within the second injection station 22 after the carrier 101 rotates.

[0092] In some embodiments, the fifth mold 17b and part 175 are moved into position above the first layer M1 and the second layer M2, as shown in Figure 20, and then the first mold 11a, the fifth mold 17b and part 175 are moved toward the first layer M1 and the second layer M2 until the fifth mold 17b engages with the second mold 14. In some embodiments, the molding apparatus 200 is positioned below the second extrusion system.

[0093] In some embodiments, molding method M20 includes step O207, which includes engaging third mold 11c with second mold 14 to form second mold cavity 19b defined by second mold 14, third mold 11c, and fifth mold 17b.

[0094] In some embodiments, the position control mechanism 20 hinges the third mold 11c around the first axis C1 along the first direction R1 toward the second mold 14, or moves the second mold 14 linearly toward the third mold 11c to engage the third mold 11c with the second mold 14.

[0095] In some embodiments, the position control mechanism 20 pivots the first mold 11a and the third mold 11c about the second axis C2 along the second direction R2 to position the third mold 11c above the second mold 14. In some embodiments, the pivoting and hinge rotation are performed separately in sequence.

[0096] In some embodiments, as shown in FIG. 21 , the third mold 11c and the fifth mold 17b engage with the second mold 14 to form a second mold cavity 19b. In some embodiments, the molding apparatus 200, including the second mold cavity 19b, is in a second closed configuration. In some embodiments, a part 175 is disposed within the second mold cavity 19b. In some embodiments, the part 175 surrounds the fifth mold 17b and is above the first layer M1 and the second layer M2. In some embodiments, the part 175 is surrounded by the second mold 14. In some embodiments, the part 175 is disposed between the fifth mold 17b and the second mold 14. In some embodiments, the second mold cavity 19b is defined by the part 175, the first layer M1, and the second layer M2.

[0097] In some embodiments, both ends 176, 177 of part 175 are attached to outer intermediate mold 15. In some embodiments, a barrier layer (not shown) is configured to prevent gas or fluid within second mold cavity 19b from escaping second mold cavity 19b.

[0098] In some embodiments, the molding method M20 includes a step O208 that includes injecting a third polymeric material into the second mold cavity 19b onto the first layer M1 and the second layer M2 to form a molded article 178 that includes the first layer M1, the second layer M2, and a third layer M3 from the third polymeric material.

[0099] In some embodiments, the third polymeric material is injected into molding apparatus 200 at second injection station 22 from a second extrusion system, as shown in Figure 22. In some embodiments, the third polymeric material is injected into molding apparatus 200 through a third mold 11c.

[0100] In some embodiments, a third polymeric material is injected into the second mold cavity 19b through one of the second inlets 12b. In some embodiments, the third polymeric material comprises thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or any other suitable material. In some embodiments, the third polymeric material comprises a physical blowing agent, such as a supercritical fluid. In some embodiments, the physical blowing agent is gaseous nitrogen, carbon dioxide, or the like. In some embodiments, the third polymeric material is foamable or microfoamable. In some embodiments, the composition of the third polymeric material may be similar to or different from the composition of the first polymeric material or the composition of the second polymeric material.

[0101] In some embodiments, the third layer M3 is attached to the part 175, the first layer M1, and the second layer M2. In some embodiments, the third layer M3 is disposed on the first layer M1 and the second layer M2, and the part 175 is disposed on the third layer M3. In some embodiments, the part 175, the first layer M1, the second layer M2, and the third layer M3 form a molded article 178. In some embodiments, the molded article 178 is a shoe. In some embodiments, the density of the third layer M3 is substantially less than the density of the first layer M1. In some embodiments, the density of the third layer M3 is substantially less than the density of the second layer M2.

[0102] In some embodiments, the pressure in second mold cavity 19b is sensed prior to injection of the third polymeric material. In some embodiments, prior to injection of the third polymeric material, a third gas (not shown) is injected into second mold cavity 19b through connection point 167 until second mold cavity 19b is sensed to have a third predetermined pressure.

[0103] In some embodiments, the method further includes detecting the pressure in the second mold cavity 19b and filling the second mold cavity 19b with a third polymeric material through the second supply port 12b at a third predetermined pressure. In some embodiments, the method further includes feeding a portion of a third gas (not shown) through the connection point 167 to the second mold cavity 19b. 2The method further includes the step of discharging from the mold cavity 19b.

[0104] In some embodiments, a third force is applied to the second mold 14 toward the third mold 11c when the molding apparatus 200 is in the second closed configuration to facilitate engagement between the third mold 11c and the second mold 14. In some embodiments, the third force is applied to the second mold 14 before the injection of the third gas into the second mold cavity 19b or before the injection of the third polymeric material into the second mold cavity 19b. In some embodiments, the third force is applied to the second mold 14 during the injection of the third gas into the second mold cavity 19b or during the injection of the third polymeric material into the second mold cavity 19b. In some embodiments, the platform 23 provides the third force to the second mold 14. In some embodiments, a fourth force is configured to press the first layer M1 and the second layer M2 toward the third layer M3 and the part 175. The fourth force is provided to facilitate integration of the first layer M1, the second layer M2, the third layer M3, and the part 175.

[0105] In some embodiments, the third polymeric material is injected into the molding apparatus 200 from a second extrusion system (not shown) at a second injection station 22, as shown in FIG.

[0106] In some embodiments, molding method M20 includes step O209, which includes separating third mold 11c from second mold 14 by position control mechanism 20. In some embodiments, before separating third mold 11c from second mold 14, application of the fourth force to molding apparatus 200 is stopped.

[0107] 23, after the first layer M1, the second layer M2, the third layer M3, and the part 175 are formed, the first layer M1, the second layer M2, the third layer M3, and the part 175 are removed from the second mold cavity 19b. In some embodiments, after the molded article 178 is formed in the molding apparatus 200, the molded article 178 is removed from the second mold cavity 19b. In some embodiments, the molding apparatus 200 is in an open configuration while the molded article 178 is removed.

[0108] In some embodiments, after molded article 178 is formed, third mold 11c separates from second mold 14, so that molded article 178 having first layer M1, second layer M2, third layer M3, and part 175 can be removed from second mold 14. In some embodiments, molded article 178 having first layer M1, second layer M2, part 175, and barrier layer can be removed from molding apparatus 200.

[0109] In some embodiments, the third mold 11c, the fifth mold 17b, and the molded article 178 move away from the second mold 14. In some embodiments, the position control mechanism 20 moves the third mold 11c and the fifth mold 17b away from the second mold 14, and the molded article 178 attached to the fifth mold 17b also moves away from the second mold 14. The second distance D2 after the third mold 11c and the fifth mold 17b have been moved away from the second mold 14 is greater than zero.

[0110] In some embodiments, before moving the third mold 11c, the fifth mold 17b and the molded article 178 away from the second mold 14, the first part 151 and the second part 152 of the outer intermediate mold 15 are moved away from each other as shown in FIG. 2 to form a gap G2 between the first part 151 and the second part 152, thereby separating the molded article 178 from the outer intermediate mold 15 and allowing it to be easily removed from the second mold cavity 19b.

[0111] In some embodiments, the molding apparatus 200 transitions from the second closed configuration to the open configuration as the gap G2 is created.

[0112] In some embodiments, molding method M20 includes a step O210 that includes obtaining a molded article 178 from molding apparatus 200, the molded article 178 including first layer M1, second layer M2, and part 175.

[0113] In some embodiments, as shown in FIG. 24 , after the third mold 11c, the fifth mold 17b, and the molded article 178 move away from the second mold 14, the molded article 178 is removed from the fifth mold 17b. In some embodiments, the molded article 178, which includes the first layer M1, the second layer M2, the third layer M3, the part 175, and the barrier layer, can be removed from the fifth mold 17b. In some embodiments, the molded article 178 is removed from the fifth mold 17b by a human or a robotic arm (not shown). In some embodiments, the third mold 11c and the fifth mold 17b are tilted before removing the molded article 178 from the fifth mold 17b. In some embodiments, the third mold 11c and the fifth mold 17b are tilted by the position control mechanism 20, and the first mold 11a is also tilted.

[0114] In some embodiments, after the molded article 178 is formed and before removing the molded article 178 from the molding apparatus 200, the molding apparatus 200 is moved away from the second injection station 22, such as by rotating the carrier 101. In some embodiments, the molded article 178 is removed from the molding apparatus 200 and the carrier 101.

[0115] In some embodiments, when the third mold 11c and the fifth mold 17b are tilted, a second angle σ2 exists between the bottom surface of the fifth mold 17b and the second mold 14. In some embodiments, the second angle σ2 is in the range of 0 to 90 degrees. In some embodiments, the second angle σ2 is in the range of 20 to 70 degrees. In some embodiments, the second angle σ2 is 45 degrees when the molded article 178 is removed from the molding apparatus 200.

[0116] In some embodiments, as shown in FIG. 25 , a molded article 178 includes a first layer M1, a second layer M2, a third layer M3, and a part 175. In some embodiments, the barrier layer is removed from the molded article 178. The first layer M1 has a first density, the second layer M2 has a second density, and the third layer M3 has a third density. The first, second, and third densities may be the same or different. In some embodiments, a first interface is between the first layer M1 and the third layer M3 and has a first density gradient, and a second interface is between the second layer M2 and the third layer M3 and has a second density gradient. The first and second density gradients may be the same or different.

[0117] In the embodiment of the present disclosure, the position control mechanism is attached to the first mold 11a, the second mold 14, and the third mold 11c. The first mold 11a and the third mold 11c are rotatable about a first axis C1 by a hinge 24 of the position control mechanism 20 and about a second axis C2 perpendicular to the first axis C1 by a pivot 26 of the position control mechanism 20, and the second mold 14 is linearly movable along a rail 25 of the position control mechanism 20. The position control mechanism 20 moves the first mold 11a opposite the second mold 14 or moves the third mold 11c opposite the second mold 14. When the first mold 11a is disposed opposite the second mold 14, the third mold 11c is offset substantially perpendicularly from the first mold 11a.

[0118] The foregoing outlines features of several embodiments so that those skilled in the art may better understand aspects of the present disclosure. Those skilled in the art should appreciate that this disclosure may readily serve as a basis for designing or modifying other processes and structures to carry out the same purposes and / or achieve the same advantages of the embodiments presented herein. Those skilled in the art should also appreciate that such equivalent structures do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations can be made in the present disclosure without departing from the spirit and scope of the present disclosure.

[0119] Furthermore, the scope of the present application is not intended to be limited to the particular embodiments of the processes, machines, manufacture, compositions of matter, means, methods, and steps described herein. Those skilled in the art will readily appreciate from this disclosure that any now-existing or future-developed processes, machines, manufacture, compositions of matter, means, methods, or steps that perform substantially the same function or achieve substantially the same results as the corresponding embodiments described herein can be utilized in accordance with the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. [Explanation of symbols]

[0120] 11a First mold 11c 3rd mold 11d First end of first mold 11a 11e: second end of first mold 11a 11f: First end of third mold 11c 11g: second end of third mold 11c 12a 1st supply port 12b 2nd supply port 121a aperture 13 Lower mold 131 Upper surface of lower mold 13 14 Second mold 15 Outer intermediate mold 151 Part 1 151a: Extension of the first portion 151 152 Part 2 152a: Extension of the second portion 152 153 Inner wall of outer intermediate mold 15 16 Pressure Regulating System 161 First Gas Pipe 163 Gas Controller 167 Connection Points 17a 4th mold 17b 5th mold 173 First end of fourth mold 17a 174 Second end of fourth mold 17a 19a First mold cavity 19b Second mold cavity 20 Position control mechanism 21 First Injection Station 22 Second Injection Station 23 Platform 24 hinge 25 Rail 26 Pivot 100 Molding equipment 101 Career 175 parts 178 Molded products 200 Molding equipment, molding station 300 Injection Molding System 400 forming stations C1 1st axis C2 2nd axis D1: First distance between the first mold 11a and the second mold 14 D2: Second distance between the third mold 11c and the second mold 14 G2 gap M1 1st layer M2 2nd layer M3 3rd layer R1 1st direction R2 2nd direction R3 3rd direction σ1 1st angle σ2 2nd angle σ3 3rd angle

Claims

1. A first mold; A second mold; a first mold cavity defined by the first mold and the second mold when the first mold is positioned opposite the second mold; a position control mechanism attached to the first mold and the second mold, the first mold and the second mold can be moved individually by the position control mechanism; A molding apparatus, wherein the first mold is rotatable around a first axis by a hinge of the position control mechanism, and is rotatable around a second axis perpendicular to the first axis by a pivot of the position control mechanism.

2. A molding apparatus as described in claim 1, wherein the first mold and the second mold are movable linearly relative to each other along the rails of the position control mechanism.

3. The molding apparatus according to claim 1 , further comprising a third mold attached to the position control mechanism and movable by the position control mechanism.

4. The molding apparatus according to claim 3, wherein the third mold is rotatable around a first axis by a hinge of the position control mechanism and around a second axis perpendicular to the first axis by a pivot of the position control mechanism.

5. 4. The molding apparatus of claim 3, further comprising a second mold cavity defined by the second mold and the third mold when the third mold is positioned opposite the second mold and the first mold is offset substantially perpendicularly from the third mold.

6. a carrier having a plurality of forming stations; a molding device disposed within one of the molding stations, the molding device including a position control mechanism and a first mold, a second mold, and a third mold held by the position control mechanism; a first injection station disposed adjacent to the carrier and configured to inject a first material into a first mold cavity of the molding apparatus defined by the first mold and the second mold; An injection molding system, wherein the position control mechanism is configured to move the first mold, the second mold, and the third mold individually.

7. 7. The injection molding system of claim 6, wherein the first mold and the third mold are rotatable about hinges and pivots of the position control mechanism, the second mold is linearly movable along a rail of the position control mechanism, the hinges and pivots are disposed on the rails, and the hinges are configured to rotate the first mold and the third mold about a second axis, the first axis being perpendicular to the second axis.

8. 7. The injection molding system of claim 6, further comprising a second injection station disposed adjacent to the carrier, separated from the first injection station, and configured to inject a second material into a second mold cavity of the molding apparatus defined by the second mold and the third mold.

9. providing a molding apparatus having a first mold, a second mold, and a third mold; mating the first mold and the second mold to form a first mold cavity defined by the first mold and the second mold; injecting a first material into the first mold cavity to form a first layer from the first material in the first mold cavity; a step of separating the first mold from the second mold by a position control mechanism; engaging the third mold with the second mold to form a second mold cavity defined by the second mold and the third mold; injecting a second material into the second mold cavity over the first layer to form a molded article comprising the first layer and a second layer from the second material; and separating the third mold from the second mold by the position control mechanism, A molding method in which the first mold is rotatable around a first axis by a hinge of the position control mechanism and rotatable around a second axis perpendicular to the first axis by a pivot of the position control mechanism.

10. hinge the first mold toward the second mold; linearly moving the second mold or the first mold toward each other to engage the first mold with the second mold; The molding method according to claim 9, further comprising the step of pivoting the first mold and the third mold to position the first mold or the third mold above the second mold.

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