Injection molding system and method

Abstract

To provide an injection molding system and an injection molding method.SOLUTION: There is provided an injection molding method. There are also provided a molding device and a runner plate over the molding device. The molding device includes a first mold, a second mold over the first mold, and a mold cavity defined by the first mold and the second mold. The runner plate includes first and second runners communicable with the mold cavity and extending within the runner plate. A divider is placed within the runner plate, and the divider has a passage connectable to the first runner or the second runner. A mixture material is injected into the mold cavity through the passage and the first runner, and the mixture material fails to flow into the mold cavity through the passage and the second runner. A foamed article is formed from the mixture material inside the mold cavity.SELECTED DRAWING: Figure 1

Description

Technical Field

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[0001] Cross - reference to related applications This application claims priority to U.S. Provisional Patent Application No. 63 / 585971, filed on September 28, 2023, and U.S. Patent Application No. 18 / 748101, filed on June 20, 2024, the entire disclosures of which are incorporated herein by reference.

[0002] Technical Field The present disclosure relates to an injection molding system and an injection molding method, and more particularly to an injection molding system and an injection molding method for preventing the formation of slag or scrap in the runner of a runner plate.

Background Art

[0003] Foamed polymer materials have many advantages such as high strength, light weight, impact resistance, and heat insulation. Foamed molded products can be manufactured by injection molding or extrusion molding. For example, after melting a polymer material and mixing it with a foaming agent to form a mixture, a force or pressure is applied to the mixture to inject or extrude the mixture into the cavity of a mold, the mixture is foamed within the cavity, and then cooled to form a foamed molded product.

[0004] However, in order not to affect the formation of foamed molded products, it is necessary to improve the smooth flow of the mixture in the injection molding system. Therefore, it is necessary to improve the structure of the injection molding system and the manufacturing method of foamed molded products.

Summary of the Invention

Problems to be Solved by the Invention

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

Means for Solving the Problems

[0006] According to one embodiment of the present disclosure, an injection molding method is provided. The injection molding method includes providing a molding apparatus and a runner plate above the molding apparatus, wherein the molding apparatus includes a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold, and the runner plate is communicable to the mold cavity and includes a first runner and a second runner extending within the runner plate; arranging a first divider within the runner plate having a passage connectable to the first runner or the second runner; injecting a first mixture into the mold cavity through the passage and the first runner, wherein the first mixture does not flow into the mold cavity through the passage and the second runner; and forming a first foamed molded product from the first mixture in the mold cavity.

[0007] According to one embodiment of the present disclosure, an injection molding method is provided. The injection molding method includes the steps of providing a molding apparatus and a runner plate above the molding apparatus, wherein the molding apparatus includes a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold, and the runner plate is communicable to the mold cavity and includes a first runner and a second runner extending within the runner plate; inserting a first plug into the first runner; injecting a first mixture into the mold cavity through the second runner, wherein the first mixture does not flow into the mold cavity through the first runner; and forming a first foamed molded product from the first mixture in the mold cavity.

[0008] According to one embodiment of the present disclosure, an injection molding system is provided. The injection molding system includes a molding apparatus, a runner plate, and a divider. The molding apparatus includes a first mold, a second mold located above the first mold, and a mold cavity defined by the first mold and the second mold engaged with the first mold. The runner plate is located above the molding apparatus and is communicable to the mold cavity and includes a first runner and a second runner extending within the runner plate. The divider is located within the runner plate and has a passage connectable to either the first runner or the second runner. The divider is configured to block the flow of a mixture into the mold cavity through one of the first and second runners, and to allow the flow of the mixture into the mold cavity through the passage and the other of the first and second runners. [Brief explanation of the drawing]

[0009] The aspects of this disclosure will be best understood from the following detailed description with reference to the accompanying drawings. It should be noted that, in accordance with standard industry practice, various features are not depicted to a constant scale. In fact, for clarity in the description, the dimensions of various features may be enlarged or reduced as appropriate.

[0010] [Figure 1] This is a schematic diagram of an injection molding system according to some embodiments of the present disclosure. [Figure 2] This is a front perspective view of an injection molding system according to some embodiments of the present disclosure. [Figure 3] This is a front perspective view of an injection molding system according to some embodiments of the present disclosure. [Figure 4] Figure 2 shows an upper cross-sectional view of a runner plate along line A-A' according to some embodiments of the present disclosure. [Figure 5] This is a side perspective view of an injection molding system along line B-B' in Figure 2, according to some embodiments of the present disclosure. [Figure 6]This is a front perspective view of an injection molding system according to some embodiments of the present disclosure. [Figure 7] Figure 6 shows an upper cross-sectional view of a runner plate along line A-A' according to some embodiments of the present disclosure. [Figure 8] Figure 6 shows an upper cross-sectional view of a runner plate along line A-A' according to some embodiments of the present disclosure. [Figure 9] This is a front perspective view of an injection molding system according to some embodiments of the present disclosure. [Figure 10] Figure 9 shows an upper cross-sectional view of a runner plate along line A-A' according to some embodiments of the present disclosure. [Figure 11] This is a front perspective view of an injection molding system according to some embodiments of the present disclosure. [Figure 12] Figure 11 shows an upper cross-sectional view of a runner plate along line A-A' according to some embodiments of the present disclosure. [Figure 13] Figure 11 shows an upper cross-sectional view of a runner plate along line A-A' according to some embodiments of the present disclosure. [Figure 14] This is a front perspective view of an injection molding system according to some embodiments of the present disclosure. [Figure 15] Figure 14 shows an upper cross-sectional view of a runner plate along line A-A' according to some embodiments of the present disclosure. [Figure 16] Figure 14 shows an upper cross-sectional view of a runner plate along line A-A' according to some embodiments of the present disclosure. [Figure 17] This flowchart shows an injection molding method according to some embodiments of the present disclosure. [Figure 18] This is a schematic cross-sectional view showing exemplary steps of the injection molding method shown in Figure 17, according to one embodiment of the present disclosure. [Figure 19] This is a schematic cross-sectional view showing exemplary steps of the injection molding method shown in Figure 17, according to one embodiment of the present disclosure. [Figure 20] This is a schematic cross-sectional view showing exemplary steps of the injection molding method shown in Figure 17, according to one embodiment of the present disclosure. [Figure 21] Schematic cross-sectional view showing exemplary stages of the injection molding method of FIG. 17, according to one embodiment of the present disclosure. [Figure 22] Schematic cross-sectional view showing exemplary stages of the injection molding method of FIG. 17, according to one embodiment of the present disclosure. [Figure 23] Flowchart showing an injection molding method according to some embodiments of the present disclosure. [Figure 24] Schematic cross-sectional view showing exemplary stages of the injection molding method of FIG. 23, according to one embodiment of the present disclosure. [Figure 25] Schematic cross-sectional view showing exemplary stages of the injection molding method of FIG. 23, according to one embodiment of the present disclosure. [Figure 26] Schematic cross-sectional view showing exemplary stages of the injection molding method of FIG. 23, according to one embodiment of the present disclosure. <00^00096>Schematic cross-sectional view showing exemplary stages of the injection molding method of FIG. 23, according to one embodiment of the present disclosure. <000009^8>Schematic cross-sectional view showing exemplary stages of the injection molding method of FIG. 23, according to one embodiment of the present disclosure. [[ID=2^4]] [Figure 29] Schematic cross-sectional view showing exemplary stages of the injection molding method of FIG. 23, according to one embodiment of the present disclosure. [Figure 30] Schematic cross-sectional view showing exemplary stages of the injection molding method of FIG. 23, according to one embodiment of the present disclosure. [Figure 31] Schematic cross-sectional view showing exemplary stages of the injection molding method of FIG. 23, according to one embodiment of the present disclosure. [Figure 32] Schematic cross-sectional view showing exemplary stages of the injection molding method of FIG. 23, according to one embodiment of the present disclosure.

MODE FOR CARRYING OUT THE INVENTION

[0011] The following disclosure provides many different embodiments or examples for carrying out different features of the subject matter provided. Hereinafter, in order to simplify the disclosure, specific embodiments of components and arrangements are described. Naturally, these are merely embodiments and not intended to be limiting. For example, the formation of a first feature above or on a second feature in the following description may include embodiments in which the first and second features are formed in direct contact, or it may include embodiments in which an additional feature is formed between the first and second features so that they do not come into direct contact. Furthermore, the disclosure may repeat reference numerals and / or reference letters in various embodiments. This repetition is for simplification and clarity and does not, in itself, indicate relationships between the various embodiments and / or configurations described.

[0012] Furthermore, spatially relative terms such as “down,” “below,” “bottom,” “up,” and “top” may be used herein to facilitate descriptions of relationships between one element or feature and another element (or multiple elements) or feature (or multiple features), 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° or in other orientations), and the spatially relative descriptors used herein may be interpreted accordingly.

[0013] Although the numerical ranges and parameters representing the broad scope of this disclosure are approximations, the numerical values ​​shown in specific examples are reported as accurately as possible. However, every numerical value inherently contains some error, which is necessarily due to the standard deviation observed in each test measurement. Furthermore, the term “about” as used herein generally means within 10%, 5%, 1%, or 0.5% of a given value or range. Alternatively, the term “about” means, as considered by those skilled in the art, within the acceptable standard error of the mean. Except for the operating examples / executions, or unless otherwise specified, all numerical ranges, quantities, values, and percentages concerning quantities, times, temperatures, operating conditions, ratios of quantities, etc., of materials disclosed herein should be understood in all cases to be modified by the term “about.” Therefore, unless otherwise indicated, the numerical parameters shown in this disclosure and the appended claims are approximations that may vary as needed. At a minimum, each numerical parameter should be interpreted by applying common rounding techniques, taking into account the reported number of significant figures. In this specification, scope can be expressed as from one endpoint to another, or between two endpoints. Unless otherwise specified, all scope disclosed herein encompasses endpoints.

[0014] Figure 1 is a schematic diagram of an injection molding system 10 according to some embodiments of the present disclosure. The injection molding system 10 includes a melting unit 110, a mixing unit 120, an injection unit 130, an injector 101 communicating with the injection unit 130, a runner plate 103 in which runners are embedded, and a molding device 105 communicating with runners in the runner plate 103.

[0015] The melting unit 110 is configured to produce a molten polymer material (such as thermoplastic polyurethane (TPU), polyurethane (PU), or plastic). The polymer material is then delivered to the mixing unit 120 via at least one delivery channel 112. The mixing unit 120 is configured to produce a mixture of the polymer material and a physical blowing agent (e.g., gaseous nitrogen, carbon dioxide, or supercritical fluid). The mixture is foamy or slightly foamy. The mixture is then delivered to the injection unit 130 via at least one delivery channel 122. The injection unit 130 is configured to eject the mixture to the molding apparatus 105 via the injection unit 130 and the runner plate 103.

[0016] Figure 2 is a front perspective view of an injection molding system 100 according to some embodiments of the present disclosure.

[0017] In some embodiments, the molding apparatus 105 is configured to form a molded article containing a polymer material. In some embodiments, the molding apparatus 105 includes a first mold 105c, a second mold 105d, at least one feed port 105a penetrating the second mold 105d, and at least one mold cavity 105b defined by the first mold 105c and the second mold 105d when the molding apparatus 105 is closed (i.e., the first mold 105c is engaged with the second mold 105d). In some embodiments, the first mold 105c is the lower mold, and the second mold 105d is the upper mold, positioned above the first mold 105c. In some embodiments, each mold cavity 105b is in communication with at least one feed port 105a. In some embodiments, the molded article is formed by physical foaming within the molding apparatus 105. The mixture undergoes physical foaming to form a foamed molded article. In some embodiments, the molded product is part of footwear (such as an outsole, insole, or midsole) or part of another product.

[0018] In some embodiments, the injector 101 has an outlet 101a for discharging the mixture. In some embodiments, the injector 101 is engageable with the runner plate 103. In some embodiments, the outlet 101a is engageable with and communicates with an inlet 103a of the runner plate 103. The mixture can flow from the outlet 101a to the inlet 103a, and along the runner 103c to a plurality of outlets 103b of the runner 103c, respectively. In some embodiments, the mixture can flow from the injector 101 to each mold cavity 105b through the runner plate 103 and the corresponding supply port 105a. In some embodiments, the mixture can flow to mold cavities 105b-1 and 105b-2 through supply ports 105a-1 and 105a-2, respectively. After being distributed to each runner 103c, the mixture enters the corresponding mold cavity 105b.

[0019] In some embodiments, each outlet 103b is able to communicate with at least one mold cavity 105b defined by the molding apparatus 105. In some embodiments, the molding apparatus 105 includes a plurality of mold cavities 105b-1 and 105b-2. The embodiment in Figure 2 shows two mold cavities 105b-1 and 105b-2, but this is not intended to limit the number of mold cavities 105b in the molding apparatus 105.

[0020] In some embodiments, a gate 104 is located at the outlet 103b of the runner plate 103. The gate 104 is configured to control the flow (velocity, flow rate, etc.) of the mixture through the outlet 103b to the mold cavity 105b. In some embodiments, when the gate 104 is open or partially open, the mixture can flow through the outlet 103b to the mold cavity 105b, and when the gate 104 is closed, the mixture cannot flow through the outlet 103b to the mold cavity 105b. The state of the gate 104 may be switched automatically or manually.

[0021] Figure 3 is a front perspective view of an injection molding system 100 according to some embodiments of the present disclosure. In the embodiment of Figure 3, the injection molding system 100 further includes a sprue 102 that is engageable with an injector 101. Since the outlet 101a of the injector 101 is engageable with the inlet 102a of the sprue 102, the mixture can flow from the injector 101 into the sprue 102. In some embodiments, the sprue 102 is at least partially surrounded by a runner plate 103. In some embodiments, the sprue 102 is positioned above the runner 103c. The sprue 102 is configured to facilitate engagement between the injector 101 and the runner plate 103. The mixture can flow from the inlet 102a of the sprue 102 towards the outlet 102b. In some embodiments, the outlet 102b of the sprue 102 is engageable with and communicates with the inlets 103a of a plurality of runners 103c. Each mixture can flow from the inlet 103a of the runner 103c along the runner 103c toward a plurality of outlets 103b. In some embodiments, as shown in Figure 3, the mixture can flow from the injector 101 through the sprue 102, the runner plate 103, and the corresponding supply port 105a into each mold cavity 105b.

[0022] Figure 4 shows a top cross-sectional view of a runner plate 103 along line A-A' in Figure 2, according to some embodiments of the present disclosure. In some embodiments, the runner plate 103 may be heated by a heater, coil, etc., to maintain the runners 103c at a specific temperature and keep the mixture flowable. In some embodiments, each runner 103c extends within the runner plate 103. Each runner 103c connects its inlet 103a to its respective outlet 103b. Figure 4 shows six runners 103c extending within the runner plate 103, but is not intended to limit the number of runners 103c within the runner plate 103. Furthermore, it is not intended to limit the configuration or design of the runners 103c. In some embodiments, the inlet 103a connects to runners 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, and 103c-6. In some embodiments, runners 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, and 103c-6 are connected to outlets 103b-1, 103b-2, 103b-3, 103b-4, 103b-5, and 103b-6, respectively.

[0023] Runners 103c may have the same or different dimensions (width, diameter, length, etc.). In some embodiments, runners 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, and 103c-6 may have the same width, diameter, and length. In some embodiments, runners 103c may be divided into multiple groups having different dimensions, with each group of runners 103c having individual dimensions (width, diameter, length, etc.).

[0024] Figure 5 is a side perspective view of an injection molding system 100 along line B-B' in Figure 2, according to some embodiment of the present disclosure. In the embodiment of Figure 5, the mixture can flow from the injector 101 into the mold cavity 105b-1 through outlets 103b-1, 103b-3, 103b-5 of the runner plate 103 and the corresponding feed ports 105a-1, 105a-3, 105a-5. Figure 5 shows that each mold cavity 105b corresponds to three outlets 103b, but it is not intended to limit the number of outlets 103b corresponding to one mold cavity 105b.

[0025] Figure 6 is a front perspective view of an injection molding system 100 according to some embodiment of the present disclosure. In the embodiment of Figure 6, a plug 106 is positioned within a runner plate 103. Figure 7 shows a top cross-sectional view of the runner plate 103 along line A-A' in Figure 6, according to some embodiment of the present disclosure.

[0026] In some embodiments, the plug 106 is a plastic block, a metal block, etc. In some embodiments, the plug 106 is inserted into the runner 103c to prevent the mixture from flowing through the runner 103c. In some embodiments, the plug 106 is temporarily fixed within the runner 103c and is removable from the runner 103c. For example, because the plug 106 is placed in the runner 103c-1, the mixture cannot flow through the runner 103c-1 into the mold cavity 105b-1, but can flow through the other runners 103c-3 and 103c-5 into the mold cavity 105b-1. In some embodiments, the plug 106 may be placed or removed when the runner plate 103 engages with the molding apparatus 105. In some embodiments, the plug 106 may be placed or removed when the runner plate 103 is disengaged from the molding apparatus 105. In some embodiments, the plug 106 may be placed or removed when the sprue 102 in Figure 3 is removed from the runner plate 103.

[0027] When the mixture is injected into the mold cavity 105b, some of the mixture may remain in the runner 103c (for example, because the mixture is viscous). The mixture remaining in the runner 103c may prevent, and even block, the mixture subsequently injected from the injector 101 from flowing through the runner 103c. In other words, the mixture for the next shot may not flow or may not be able to flow smoothly into the mold cavity 105b. Since the plugs 106 can be placed or removed as needed, it is possible to prevent the formation of slag or scrap of the mixture in the runner 103c and to avoid residual mixture remaining in the runner 103c for a long time. Furthermore, the number of runners 103c used can be easily adjusted simply by adding or removing the plugs 106 without changing to a different runner plate 103 with a different configuration. As a result, manufacturing costs and manpower can be saved. In some embodiments, the plugs 106 may be placed or removed manually or remotely.

[0028] Figure 8 shows how multiple plugs 106 are positioned within runners 103c-1 and 103c-4, respectively. It will be understood that this is not intended to limit the number of plugs 106. In some embodiments, the plugs 106 may be positioned or removed manually or by a robotic arm, etc. In some embodiments, the plugs 106 are replaced periodically. For example, after a plug is removed from runner 103c-1, another plug is reinserted into runner 103c-1.

[0029] Figure 9 is a front perspective view of an injection molding system 100 according to some embodiment of the present disclosure. In the embodiment of Figure 9, a divider 107 is positioned within a runner plate 103. Figure 10 shows a top cross-sectional view of the runner plate 103 along line A-A' in Figure 9, according to some embodiment of the present disclosure.

[0030] In some embodiments, the mixture may be distributed to each runner 103c by a divider 107. In some embodiments, the mixture may be evenly distributed to each runner 103c by the divider 107. In some embodiments, the divider 107 includes an inlet 107a, a plurality of outlets 107b, and a plurality of passages 107c between the inlet 107a and the outlets 107b. Since the inlet 107a of the divider 107 is connected to the inlet 103a of the runner plate 103, the mixture can flow from the injector 101 through the divider 107 to the runners 103c. Each passage 107c corresponds to one outlet 107b. In the embodiment shown in Figure 10, the six passages 107c-1, 107c-2, 107c-3, 107c-4, 107c-5, and 107c-6 are connected to exits 107b-1, 107b-2, 107b-3, 107b-4, 107b-5, and 107b-6, respectively. It will be understood that there is no intention to limit the number of passages 107c, as long as the number of passages 107c corresponds to the number of exits 107b. In some embodiments, the divider 107 is a splitter, etc. In some embodiments, the divider 107 is rotatable with respect to the runner 103c and runner plate 103. In some embodiments, the divider 107 is rotatable manually or remotely. In some embodiments, the divider 107 is rotatable by a robotic arm, etc. In some embodiments, the dimensions of the runner 103c (e.g., width, diameter, length, etc.) are substantially larger than the dimensions of the passages 107c.

[0031] In some embodiments, the divider 107 is temporarily fixed within the runner 103c and is removable from the runner 103c. When a single shot of mixture is injected into the mold cavity 105b, some of the mixture may remain in the runner 103c due to its viscosity. The mixture remaining in the runner 103c then cools and solidifies, which can prevent, and even block, the next shot of mixture from flowing through the passage 107c. In other words, the next shot of mixture may not flow or may not be able to flow smoothly into the mold cavity 105b. Such problems can be solved simply by removing the divider 107 from the runner plate 103 and replacing it with another new divider 107. Since the divider 107 can be positioned or removed as needed, residual mixture can be avoided remaining in the runner 103c for extended periods. Furthermore, the number of runners 103c used can be easily adjusted simply by changing the divider 107 to a different configuration (e.g., a different number of passages 107c) without changing to a different runner plate 103. As a result, manufacturing costs and manpower can be saved. In some embodiments, the divider 107 may be placed or removed manually or remotely. In some embodiments, the divider 107 may be replaced or removed by a robotic arm or the like.

[0032] Figure 11 is a front perspective view of an injection molding system 100 according to some embodiment of the present disclosure. In the embodiment of Figure 11, a block 108 is positioned within a passage 107c of a divider 107. Figure 12 shows a top cross-sectional view of a runner plate 103 along line A-A' in Figure 11, according to some embodiment of the present disclosure.

[0033] In some embodiments, block 108 is inserted into passage 107c of divider 107 to prevent the mixture from flowing through passage 107c. In some embodiments, block 108 is a plastic block, a metal block, etc. In some embodiments, block 108 is temporarily fixed in passage 107c and removable from passage 107c. For example, if block 108 is placed in passage 107c-1, the mixture cannot flow into mold cavity 105b-1 through passage 107c-1 and runner 103c-1, but can flow into mold cavity 105b-1 through passages 107c-3, 107c-5 and the corresponding runners 103c-3, 103c-5. Since block 108 can be placed or removed as needed, it is possible to prevent the formation of slag or scrap of the mixture in runner 103c and minimize or avoid any residual mixture remaining in runner 103c. Furthermore, the number of runners 103c used can be easily adjusted simply by adding or removing blocks 108, without having to change to a different runner plate 103. As a result, manufacturing costs and labor can be saved.

[0034] Figure 13 shows a top cross-sectional view of a runner plate 103 along line A-A' in Figure 11, according to some embodiments of the present disclosure. In the embodiment of Figure 13, more blocks 108 are arranged in passages 107c-1 and 107c-6, respectively. It will be understood that this is not intended to limit the number of blocks 108. In some embodiments, the blocks 108 may be placed or removed manually or remotely. In some embodiments, the blocks 108 may be placed or removed by a robotic arm or the like.

[0035] In some embodiments, instead of placing block 108 within the passage 107c of the divider 107 to prevent the mixture from flowing through passage 107c, the divider 107 is configured to have fewer passages 107c (for example, compared to the number of runners 103c).

[0036] Figure 14 is a front perspective view of an injection molding system 100 according to some embodiment of the present disclosure. Figure 15 shows a top cross-sectional view of a runner plate 103 along line A-A' in Figure 14, according to some embodiment of the present disclosure.

[0037] In the embodiments shown in Figures 14 and 15, the divider 107 is configured to have a small number of passages 107c. For example, since the divider 107 does not have passage 107c-1 (shown in Figure 13), the mixture cannot flow into runner 103c-1. In other words, the divider 107 is designed to block runner 103c-1. In this embodiment, when the divider 107 is placed within the runner plate 103, passages 107c-2 to 170c-6 are configured to align with runners 103c-2 to 103c-6, but not with runner 103c-1.

[0038] In some embodiments, the divider 107 is rotatable within the runner 103c, and is designed to block one or more runners 103c. For example, rotating the divider 107 in Figure 15 clockwise (e.g., about 15°) blocks runner 103c-5, while runner 103c-1 becomes open to the passage 107c-3. Thus, rotation of the divider 107 allows for the selection of the mixture flowing through the runner 103c. In some embodiments, the divider 107 can have various configurations.

[0039] Figure 16 shows another configuration of the divider 107 according to some embodiments of the present disclosure. In Figure 16, the divider 107 is provided with four passages 107c, so that two of the runners 103c are blocked. It will be understood that this is not intended to limit the number of passages 107c. If the divider 107 in Figure 16 is rotated clockwise (for example, by about 15°), runners 103c-5 and 103c-4 are blocked by the divider 107, and runners 103c-1, 103c-2, 103c-3 and 103c-6 become able to communicate with the corresponding passages 107c-3, 107c-4, 107c-5 and 107c-6.

[0040] Figure 17 is a flowchart of an injection molding method 200 according to some embodiments of the present disclosure. The injection molding method 200 includes steps S210 to S250, and the description and illustrations are not limited to the order of steps S210 to S250. Figures 18 to 22 are schematic cross-sectional views of various stages of the injection molding method 200. In some embodiments, the steps of the injection molding method 200 can be automatically repeated. In some embodiments, the injection molding method 200 is performed by the injection molding system 100 of Figure 1.

[0041] In step S210, a molding apparatus 105 and a runner plate 103 are provided. In some embodiments, the molding apparatus 105 includes a first mold 105c, a second mold 105d, and a mold cavity 105b defined by the first mold 105c and the second mold 105d engaged with each other, and the runner plate 103 includes a plurality of runners 103c extending within the runner plate 103. In step S220, a plug is inserted into the first runner 103c of the runners 103c. In step S230, the injection unit 130 is configured to inject a mixture from the mixing unit 120 through the injector 101 and the runners 103c other than the first runner 103c (i.e., the runner 103c with the plug inserted) into the mold cavity 105b of the molding apparatus 105, and then in step S240, a foamed molded product is formed from the mixture. It should be noted that the mixture cannot flow from the injection unit 130 through the first runner 103c into the mold cavity 105b. In step S250, after forming the foamed molded product, the plug is removed from the first runner 103c of the runner plate 103. When the runner plate 103 is placed on the molding apparatus 105, the plug is either insertable into or removable from the runner 103c.

[0042] In some embodiments, before inserting the plug in step S220, or after removing the plug in step S250, the injection unit 130 is configured to inject the mixture (or another mixture) through the injector 101 and all the runners 103c into the mold cavity 105b, which then forms another foamed molded product from the mixture.

[0043] In some embodiments, after forming the foamed product in step S240, an additional plug is inserted into one of the runners 103c other than the first runner, and then step S250 is performed or skipped for the next injection (or next shot) of the mixture.

[0044] Figure 18 is a front perspective view of an injection molding system 100 according to some embodiments of the present disclosure. The injection molding system 100 includes an injector 101, a runner plate 103, and a molding apparatus 105. Next, as shown in Figure 19, the injector 101 engages with the runner plate 103, and the molding apparatus 105 engages with the runner plate 103. As shown in Figure 19, the first mold 105c of the molding apparatus 105 engages with the second mold 105d of the molding apparatus 105. The molding apparatus 105 becomes a closed configuration. After the first mold 105c and the second mold 105d engage, at least one mold cavity 105b is formed. In some embodiments, the outlet 101a of the injector 101 is aligned with the outlet 103b of the runner plate 103, so that the injector 101 can communicate with the mold cavity 105b via the runner plate 103. In some embodiments, the outlets 103b-1 and 103b-2 are able to communicate with the mold cavities 105b-1 and 105b-2, respectively.

[0045] In some embodiments, as shown in Figure 20, the plug 106 is inserted into the runner 103c extending within the runner plate 103. In some embodiments, as shown in Figures 20 and 7, the plug 106 is inserted into the runner 103c-1. In some embodiments, the plug 106 is inserted before or after the engagement of the runner plate 103 with the molding apparatus 105. As shown in Figure 21, after the plug 106 is inserted, the mixture M is injected from the injector 101 through the runner plate 103 into the mold cavity 105b. In some embodiments, as shown in Figure 7, the one-shot mixture M is injected through runners 103c-3 and 103c-5 into the mold cavity 105b-1, and through runners 103c-2, 103c-4 and 103c-6 into the mold cavity 105b-2. In some embodiments, the gates 104 at outlets 103b-3 and 103b-5 may be adjusted to increase the flow rate or flow rate of the mixture M flowing into the mold cavity 105b-1. In some embodiments, the gates 104 at outlets 103b-2, 103b-4, and 103b-6 may be adjusted to decrease the flow rate or flow rate of the mixture M flowing into the mold cavity 105b-2.

[0046] After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M undergoes physical foaming to become a foamed molded product. After the foamed molded product is formed, the engagement between the first mold 105c and the second mold 105d is released as shown in Figure 22, and the foamed molded product is removed from the molding apparatus 105. In some embodiments, the plug 106 is removed from the runner 103c as shown in Figure 22.

[0047] Figure 23 is a flowchart of an injection molding method 300 according to some embodiments of the present disclosure. The injection molding method 300 includes steps S310 to S350, and the description and illustrations are not limited to the order of steps S310 to S350. Figures 24 to 32 are schematic cross-sectional views of various stages of the injection molding method 300. In some embodiments, the steps of the injection molding method 300 can be automatically repeated. In some embodiments, the injection molding method 300 is performed by the injection molding system 100 of Figure 1.

[0048] In step S310, a molding apparatus 105 and a runner plate 103 are provided. In some embodiments, the molding apparatus 105 includes a first mold 105c, a second mold 105d, and a mold cavity 105b defined by the first mold 105c and the second mold 105d engaged with each other, and the runner plate 103 includes a first runner 103c and a second runner 103c extending within the runner plate 103. In step S320, a divider having a passage connectable to the first runner 103c or the second runner 103c is placed within the runner plate 103. Furthermore, the passage is alignable with the first runner or the second runner. In step S330, an injection unit 130 is configured to inject a mixture from a mixing unit 120 through an injector 101, the passage and the first runner 103c into the mold cavity 105b of the molding apparatus 105, and then in step S340, a foamed molded product is formed from the mixture. It should be noted that the mixture cannot flow from the injection unit 130 through the passage and the second runner 103c into the mold cavity 105b. In step S350, after forming the foamed molded product, the divider is removed from the runner plate 103. When the runner plate 103 is placed on the molding apparatus 105, the divider is either insertable into or removable from the runner plate 103.

[0049] In some embodiments, before the divider is placed in step S320, the injection unit 130 is configured to inject the mixture (or another mixture) into the mold cavity 105b through the injector 101, the first runner 103c and the second runner 103c, and then to form another foamed molded product from the mixture. In some embodiments, after the divider is removed from the runner plate 103, an additional divider is placed in the runner plate 103, the additional divider having a different configuration from the removed divider.

[0050] In some embodiments, when a divider is placed within the runner plate 103, the divider's passage is aligned with the first runner but not with the second runner. In some embodiments, when a divider is placed within the runner plate 103 for the next injection of the mixture, the divider is rotatable relative to the runner plate 103. For example, after rotating the divider, the divider's passage changes from being aligned with the first runner to being aligned with the second runner and not aligned with the first runner.

[0051] In some embodiments, the injection molding method 300 includes the step of inserting a divider 107 into the runner 103c, as shown in Figure 24. In some embodiments, the divider 107 is inserted before or after the engagement of the runner plate 103 with the molding apparatus 105. In some embodiments, the inlet 103a of the runner plate 103 is aligned with the inlet 107a of the divider 107, and the outlet 107b of the divider 107 is in communication with the outlet 103b of the runner plate 103. After inserting the divider 107, as shown in Figure 25, the mixture M is injected from the injector 101 through the runner plate 103 into the mold cavity 105b. In some embodiments, as shown in Figures 25 and 10, the one-shot mixture M is injected into mold cavity 105b-1 through runners 103c-1, 103c-3, and 103c-5, and into mold cavity 105b-2 through runners 103c-2, 103c-4, and 103c-6. In some embodiments, the divider 107 evenly distributes the one-shot mixture M to runners 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, and 103c-6. Thus, as shown in Figure 25, the amount of mixture M entering mold cavity 105b-1 is substantially the same as the amount of mixture M entering mold cavity 105b-2.

[0052] After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M undergoes physical foaming to become a foamed molded product. After the foamed molded product is formed, it is removed from the molding apparatus. In some embodiments, the divider 107 is removed from the runner 103c if it is no longer needed, needs to be changed to a different divider 107 with a different configuration, or needs to be replaced with a new divider 107.

[0053] In some embodiments, the injection molding method 300 includes the step of inserting block 108 into the passage 107c of divider 107, as shown in Figure 26. In some embodiments, block 108 is inserted before or after engagement of runner plate 103 with molding apparatus 105. In some embodiments, as shown in Figure 27, a one-shot mixture M is injected into mold cavity 105b-1 through runners 103c-3 and 103c-5, and into mold cavity 105b-2 through runners 103c-2, 103c-4, and 103c-6. In some embodiments, the gates 104 of outlets 103b-3 and 103b-5 may be adjusted to increase the flow rate or flow rate of mixture M flowing into mold cavity 105b-1. In some embodiments, the gates 104 at outlets 103b-2, 103b-4, and 103b-6 may be adjusted to slow down the flow rate or reduce the flow rate of the mixture M flowing into the mold cavity 105b-2.

[0054] After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M undergoes physical foaming to become a foamed molded product. After the foamed molded product is formed, it is removed from the molding apparatus. In some embodiments, if block 108 is no longer needed, it is removed from the divider 107.

[0055] In some embodiments, the divider 107 rotates as needed (e.g., by selecting runner 103c to be used as needed). For example, as the divider 107 rotates clockwise (together with block 108), runner 103c-2 is blocked, as shown in Figures 28 and 29. Figure 29 shows a top cross-sectional view along line A-A' in Figure 28. After rotation, as shown in Figure 30, the one-shot mixture M is injected into mold cavity 105b-1 through runners 103c-1, 103c-3 and 103c-5, and into mold cavity 105b-2 through runners 103c-4 and 103c-6. In some embodiments, the gates 104 at outlets 103b-4 and 103b-6 may be adjusted to increase the flow velocity or flow rate of the mixture M flowing into mold cavity 105b-2. In some embodiments, the gates 104 at outlets 103b-1, 103b-3, and 103b-5 may be adjusted to slow down the flow rate or reduce the flow rate of the mixture M entering the mold cavity 105b-1. After the mixture M enters the mold cavities 105b-1 and 105b-2, it undergoes physical foaming to become a foamed molded product. After the foamed molded product is formed, it is removed from the molding apparatus.

[0056] In some embodiments, dividers 107 with different configurations are inserted into the runner 103c, as shown in Figures 31 and 16. In some embodiments, the dividers 107 are inserted before or after the engagement of the injector 101 and the runner plate 103. In some embodiments, the dividers 107 are inserted before or after the engagement of the first mold 105c and the second mold 105d. In some embodiments, the dividers 107 shown in Figures 31 and 16 do not have passages 107c-1 and 107c-2. That is, as shown in Figure 32, the mixture M is injected into the mold cavity 105b-1 through runners 103c-3 and 103c-5, and into the mold cavity 105b-2 through runners 103c-4 and 103c-6. In some embodiments, the divider 107 evenly distributes the one-shot mixture M to runners 103c-3, 103c-4, 103c-5, and 103c-6. After the mixture M enters the mold cavities 105b-1 and 105b-2, it undergoes physical foaming to become a foamed molded product. After the foamed molded product is formed, it is removed from the molding apparatus. In some embodiments, the divider 107 is removed from runner 103c.

[0057] In embodiments of the present disclosure, interchangeable plugs or interchangeable dividers are used in injection molding systems. In some embodiments, plugs are inserted into runners on a runner plate to block runners as needed and prevent the formation of slag or scrap within the runners. In some embodiments, dividers are placed between the sprue and the runners on the runner plate to guide the molding material to selected runners, to easily change the number of runners used within the runner plate, and to easily remove any molding material residue that remains in the runners for extended periods.

[0058] The foregoing outlines some features of embodiments so that those skilled in the art may better understand aspects of the disclosure. Those skilled in the art should understand that the disclosure can be readily used as a basis for designing or modifying other processes and structures to perform the same purposes and / or achieve the same advantages as the embodiments described herein. Furthermore, those skilled in the art should understand that such equivalent structures can be modified, substituted, and altered herein without departing from the spirit and scope of the disclosure.

[0059] Furthermore, the scope of this application is not intended to be limited to specific embodiments of the processes, machines, products, compositions, means, methods, and steps described herein. Those skilled in the art will readily understand from the disclosures herein that existing or future-developed processes, machines, products, compositions, means, methods, or steps that perform substantially the same functions or achieve substantially the same results as the corresponding embodiments described herein may be used in accordance with this disclosure. Accordingly, the appended claims are intended to include such processes, machines, products, compositions, means, methods, and steps within their scope. [Explanation of Symbols]

[0060] 10. Injection molding system 101 Injector 101a Outlet of injector 101 102 Sprue 102a Entrance to Sprue 102 102b Exit of Sprue 102 103 Runner Plate 103a Runner 103c entrance 103b Runner 103c Exit 103b-1, 103b-2, 103b-3, 103b-4, 103b-5, 103b-6 exit 103c Runner 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, 103c-6 Runner Gate 104 105 Molding equipment 105a Supply port 105a-1, 105a-2, 105a-3, 105a-5 Supply port 105b Mold Cavity 105b-1, 105b-2 mold cavity 105c First mold 105d Second mold 106 plug 107 Divider 107a Entrance to Divider 107 107b Exit of Divider 107 107b-1, 107b-2, 107b-3, 107b-4, 107b-5, 107b-6 exit 107c Divider 107 passage 107c-1, 107c-2, 107c-3, 107c-4, 107c-5, 107c-6 aisle 108 blocks 110 Melting Unit 112 Delivery Channels 120 Mixing Units 122 delivery channels 130 Injection Units M mixture

Claims

1. A step of providing a molding apparatus and a runner plate located above the molding apparatus, wherein the molding apparatus includes a first mold, a second mold located above the first mold, and a mold cavity defined by the first mold and the second mold, the runner plate is in communication with the mold cavity, and includes a first runner and a second runner extending within the runner plate, The steps include: placing a first divider having a passage connectable to the first runner or the second runner within the runner plate; A step of injecting a first mixture into the mold cavity through the passage and the first runner, wherein the first mixture does not flow into the mold cavity through the passage and the second runner, A step of forming a first foamed molded product from the first mixture in the mold cavity, The process involves, before positioning the first divider, injecting the second mixture into the mold cavity through the first runner and the second runner, and forming a second foamed molded product from the second mixture within the mold cavity. An injection molding method including [a specific component].

2. After forming the first foamed molded product, the first divider is removed from the runner plate, The steps include: arranging a second divider within the runner plate; It further includes, The injection molding method according to claim 1, wherein the second divider has a different configuration from the first divider.

3. The step of placing the first divider within the runner plate is: A process of aligning the passage with the first runner, but not aligning the passage with the second runner. The injection molding method according to claim 1, further comprising:

4. The injection molding method according to claim 1, further comprising the step of inserting a block into the passage after forming the first foamed molded product.

5. The steps include rotating the first divider within the runner plate, A step of injecting a third mixture into the mold cavity through the passage and the second runner, wherein the third mixture does not flow into the mold cavity through the passage and the first runner, The process of forming a third foamed molded product from the third mixture in the mold cavity The injection molding method according to claim 1, further comprising:

6. A step of providing a molding apparatus and a runner plate located above the molding apparatus, wherein the molding apparatus includes a first mold, a second mold located above the first mold, and a mold cavity defined by the first mold and the second mold, the runner plate is in communication with the mold cavity, and includes a first runner and a second runner extending within the runner plate, The steps include inserting the first plug into the first runner, A step of injecting the first mixture into the mold cavity through the second runner, wherein the first mixture does not flow into the mold cavity through the first runner, A step of forming a first foamed molded product from the first mixture in the mold cavity, The process involves injecting the second mixture into the mold cavity through the first runner and the second runner before inserting the first plug, and forming a second foamed molded product from the second mixture within the mold cavity. An injection molding method including [a specific component].

7. After forming the first foamed molded product, the first plug is removed from the first runner, After forming the first foamed molded product, the second plug is inserted into the second runner. The injection molding method according to claim 6, further comprising:

8. After removing the first plug, A step of injecting the second mixture into the mold cavity through the first runner and the second runner, The process of forming a second foamed molded product from the second mixture in the mold cavity The injection molding method according to claim 7, further comprising:

9. A molding apparatus comprising a first mold, a second mold located above the first mold, and a mold cavity defined by the first mold and the second mold engaged with the first mold, A runner plate is positioned above the molding apparatus and includes a plurality of runners that are capable of communicating with the mold cavity and extending inside it, A divider disposed within the runner plate and having a number of passages different from the number of runners to which the plurality of runners can be connected, and Includes, An injection molding system in which the divider is configured to block the flow of a mixture into the mold cavity through at least one of the plurality of runners, and to allow the flow of the mixture into the mold cavity through the passage and at least one other of the plurality of runners.

10. The injection molding system according to claim 9, wherein the divider is rotatable with respect to the runner plate, insertable into the runner plate, and removable from the runner plate.

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