Method for manufacturing articles using an injection molding system

Abstract

To provide an article and a method for producing the same.SOLUTION: A method for producing an article includes the steps of: providing a molding apparatus having a first mold and a second mold, and placing a part between the first mold and the second mold, the part including a hollow space and an opening communicating with the hollow space; engaging the opening with the first mold or the second mold; mating the first mold with the second mold to form a mold cavity surrounding the part, the opening being engaged with a supply port of the molding apparatus configured to be in communication with the hollow space; injecting a molding material into the hollow space through the supply port and the opening, the molding material including a polymeric material and a foaming agent; and foaming the molding material to form a foam member. The foam member is in contact with an inner surface of the part.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the priority of U.S. Provisional Patent Application No. 63 / 617,410, filed on January 3, 2024, and U.S. Patent Application No. 18 / 900,906, filed on September 30, 2024, and those applications are incorporated herein by reference in their entirety.

[0002] The present invention relates to an article and a method for manufacturing the same, and particularly to an article including a foamed member in contact with a component and a method for manufacturing the same.

Background Art

[0003] An article including a foamed member and a component attached to at least a part of the foamed member has many advantages such as high strength, low weight, and impact resistance. Since the article can be manufactured by adhering the foamed member and the component, an adhesive is disposed between the foamed member and the component. However, improvement in the reliability of an article including a foamed member and a component and a method for manufacturing the article is required.

Summary of the Invention

Problems to be Solved by the Invention

[0004] An object of the present invention is to provide an article and a method for manufacturing the same.

Means for Solving the Problems

[0005] According to one embodiment of the present disclosure, a method for manufacturing an article is disclosed. The method includes providing a molding apparatus having a first mold and a second mold; positioning a component between the first mold and the second mold, the component comprising a hollow space and an opening communicating with the hollow space; engaging the opening with the first mold or the second mold; engaging the first mold with the second mold to form a mold cavity surrounding the component, the opening engaging with a supply port of the molding apparatus communicating with the hollow space. The method further includes injecting a molding material into the hollow space through the supply port and the opening, the molding material comprising a polymer material and a foaming agent; and foaming the molding material to form a foamed member. The foamed member is in contact with the inner surface of the component.

[0006] According to one embodiment of the present disclosure, a method for manufacturing an article is disclosed. The method includes providing a molding apparatus having a first mold and a second mold; arranging a component between the first mold and the second mold, the component including a hollow space and an opening communicating with the hollow space; engaging the opening with the first mold or the second mold; engaging the first mold with the second mold to form a mold cavity surrounding the component, the opening engaging with a supply port of the molding apparatus communicating with the hollow space, the supply port being located in the side wall of the molding apparatus, and the component being located within the mold cavity. The method further includes injecting a molding material into the hollow space through the supply port and the opening; and foaming the molding material to form a foamed member. The hollow space expands within the mold cavity during the formation of the foamed member. [Brief explanation of the drawing]

[0007] The aspects of this disclosure will be best understood by reading the following detailed description in conjunction with the attached drawings. Note that, in accordance with standard practice in this industry, various features are not depicted to scale. In fact, the dimensions of various features may be enlarged or reduced as appropriate for the sake of clarity in the discussion.

[0008] [Figure 1] This is a schematic diagram of an injection molding system according to one embodiment of the present invention. [Figure 2] This is a schematic diagram of a portion of the injection molding system shown in Figure 1, according to one embodiment of the present invention. [Figure 2A] This is an enlarged view of a portion of the injection molding system enclosed by the dashed line in Figure 2, according to one embodiment of the present invention. [Figure 3] This is a schematic diagram of an injection molding system according to one embodiment of the present invention. [Figure 4] This flowchart shows a method for manufacturing an article according to one embodiment of the present invention. [Figure 5A] This flowchart shows a method for manufacturing an article according to one embodiment of the present invention. [Figure 5B] This flowchart shows a method for manufacturing an article according to one embodiment of the present invention. [Figure 6] This is a schematic diagram illustrating an exemplary operation of a method for manufacturing an article according to one embodiment of the present disclosure. [Figure 7] This is a schematic diagram illustrating an exemplary operation of a method for manufacturing an article according to one embodiment of the present disclosure. [Figure 8] This is a schematic diagram illustrating an exemplary operation of a method for manufacturing an article according to one embodiment of the present disclosure. [Figure 9] This is a schematic diagram of a portion of an injection molding system according to one embodiment of the present disclosure. [Figure 10] This is a schematic diagram of a portion of an injection molding system according to one embodiment of the present disclosure. [Figure 11] This is a schematic diagram illustrating an exemplary operation of a method for manufacturing an article according to one embodiment of the present disclosure. [Figure 12] This is a schematic diagram illustrating an exemplary operation of a method for manufacturing an article according to one embodiment of the present disclosure. [Figure 13] It is a schematic diagram showing exemplary operations of a method for manufacturing an article according to an embodiment of the present disclosure. [Figure 14] It is a schematic diagram showing exemplary operations of a method for manufacturing an article according to an embodiment of the present disclosure. [Figure 15] It is a schematic diagram showing exemplary operations of a method for manufacturing an article according to an embodiment of the present disclosure. [Figure 16] It is a schematic diagram showing an exemplary article according to an embodiment of the present disclosure. [Figure 17] It is a schematic diagram showing an exemplary article according to an embodiment of the present disclosure. [Figure 18] It is a schematic cross-sectional view showing exemplary operations in a method for manufacturing an article according to an embodiment of the present disclosure. [Figure 19] It is a schematic cross-sectional view showing exemplary operations in a method for manufacturing an article according to an embodiment of the present disclosure. [Figure 20] It is a schematic cross-sectional view showing exemplary operations in a method for manufacturing an article according to an embodiment of the present disclosure. [Figure 21] It is a schematic cross-sectional view showing exemplary operations in a method for manufacturing an article according to an embodiment of the present disclosure. [Figure 22] It is a schematic cross-sectional view showing exemplary operations in a method for manufacturing an article according to an embodiment of the present disclosure. [Figure 23] It is a schematic cross-sectional view showing exemplary operations in a method for manufacturing an article according to an embodiment of the present disclosure. [Figure 24] It is a schematic cross-sectional view showing exemplary operations in a method for manufacturing an article according to an embodiment of the present disclosure.

Embodiments for Carrying Out the Invention

[0010] Furthermore, spatially relative terms such as "below", "beneath", "lower", "above", "upper", etc. may be used herein for ease of explanation to describe the relationship of one element or feature to another 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 shown in the drawings. The apparatus may be otherwise oriented (rotated ninety degrees or at other orientations), and the spatially relative descriptors used herein may likewise be interpreted accordingly.

[0011] Although the numerical ranges and parameters representing the broad scope of this disclosure are approximations, the numerical values ​​described in the specific examples are reported as accurately as possible. However, every numerical value inherently contains a certain degree of error that inevitably arises from the standard deviation observed in each test measurement. Furthermore, as used herein, the term “about” generally means within 10%, 5%, 1%, or 0.5% of a given value or range. Alternatively, “about” means within the acceptable standard error of the mean, as considered by those skilled in the art. Except in the operations / examples, or unless otherwise explicitly stated, all numerical ranges, quantities, values, and percentages disclosed herein, such as quantities of material, durations of time, temperatures, operating conditions, and ratios of quantities, should be understood in all cases to be modified by the term “about.” Therefore, unless otherwise indicated, the numerical parameters described in this disclosure and the appended claims are approximations that may vary as desired. At a minimum, each numerical parameter should be interpreted by applying common rounding techniques in light of the number of significant figures reported. Ranges may be expressed herein as from one endpoint to another, or between two endpoints. All ranges disclosed herein include endpoints unless otherwise specified.

[0012] Figure 1 is a schematic diagram of an injection molding system 200 according to one embodiment of the present invention. The injection molding system 200 includes an extrusion system 110 and a molding apparatus 100, as shown in Figure 1. The extrusion system 110 is configured to produce a molding material of a polymer material and a foaming agent. In some embodiments, the molding material is foamy or slightly foamy.

[0013] In some embodiments, the polymer material includes high molecular weight polymers. In some embodiments, the polymer material includes ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), etc. In some embodiments, the polymer material includes foaming materials. In some embodiments, the blowing agent is a physical or chemical additive that releases gas and thereby forms pores in the foamed polymer article. In some embodiments, the blowing agent is a physical blowing agent. Physical blowing agents include atmospheric gases (e.g., nitrogen or carbon dioxide), hydrocarbons, chlorofluorocarbons, noble gases, or combinations thereof. The blowing agent may be supplied in any fluid physical state, e.g., gas, liquid, or supercritical fluid (SCF).

[0014] Figure 2 is a schematic diagram of an extrusion system 110 according to an aspect of the present disclosure in several embodiments. The extrusion system 110 includes a melting unit 120, a mixing unit 130, a foaming agent supply unit 140, and an injection unit 150. In some embodiments, the extrusion system 110 further includes a first flow control element 161, a second flow control element 162, and a monitoring module 180.

[0015] In some embodiments, referring to Figure 2, the melting unit 120 is configured to transport polymer material. The melting unit 120 includes a pressing cartridge 121, a first supply passage 122, a first discharge passage 123, and a pressing member 124. In some embodiments, the melting unit 120 further includes a supply hopper 125.

[0016] In some embodiments, a first supply passage 122 and a first discharge passage 123 are located at both ends of the press cartridge 121, respectively. In some embodiments, the first supply passage 122 communicates with the internal space 1211 of the press cartridge 121, and the first discharge passage 123 communicates with the external space of the press cartridge 121, and the first supply passage 122 is configured to deliver polymer material to the internal space 1211 of the press cartridge 121. In some embodiments, a supply hopper 125 is configured to deliver polymer material to the internal space 1211 of the press cartridge 121 through the first supply passage 122.

[0017] The press member 124 is configured to transport polymer material from the first supply passage 122 to the first discharge passage 123. In some embodiments, the press member 124 is located in the internal space 1211 of the press cartridge 121. In some embodiments, the press member 124 is located in the internal space 1211 of the press cartridge 121 between the first supply passage 122 and the first discharge passage 123 and is used to bias the polymer material toward the first discharge passage 123. In some embodiments, the press member 124 is rotatable relative to the press cartridge 121. In some embodiments, the polymer material is transported from the first supply passage 122 to the first discharge passage 123 by the rotation of the press member 124. In some embodiments, the press member 124 cannot move in a direction parallel to the longitudinal axis of the press cartridge 121.

[0018] In some embodiments, the length of the press member 124 extends along the length of the press cartridge 121, and the ratio of the distance D1 between the inner sidewall 1212 of the press cartridge 121 and the press member 124 to the diameter D2 of the press member 124 is in the range of about 1:1500 to about 1:4500, and the polymer material melted by the melting unit 120 is homogenized. In some embodiments, the shortest distance D1 between the inner sidewall 1212 of the press cartridge 121 and the press member 124 is substantially 0.3 mm or less. In some embodiments, the shortest distance D1 between the inner sidewall 1212 of the press cartridge 121 and the press member 124 is in the range of 0.01 to 0.05 mm.

[0019] The mixing unit 130 is configured to receive polymer material from the melting unit 120, mix the polymer material with a foaming agent, and form a molding material of the polymer material and foaming agent. The mixing unit 130 includes a hollow mixing cartridge 131, a second supply passage 132, a second discharge passage 133, and a mixing rotor 134.

[0020] The second supply passage 132 and the second discharge passage 133 are located at both ends of the mixing cartridge 131, respectively. In some embodiments, the second supply passage 132 is configured to deliver polymer material. In some embodiments, the second discharge passage 133 is configured to discharge molding material.

[0021] The mixing rotor 134 is configured to mix the polymer material with a foaming agent to form a molding material in the mixing cartridge 131. In some embodiments, the mixing rotor 134 is located within the mixing cartridge 131. In some embodiments, the mixing rotor 134 is located within the mixing cartridge 131 between a second supply passage 132 and a second discharge passage 133 to agitate the molding material within the mixing cartridge. The mixing rotor 134 is rotatable to mix the polymer material and the foaming agent and to transport the molding material of the polymer material and foaming agent from the second supply passage 132 to the second discharge passage 133. In some embodiments, the mixing rotor 134 cannot move in a direction parallel to the longitudinal axis of the mixing cartridge 131.

[0022] In some embodiments, the length of the mixing rotor 134 extends along the length of the hollow mixing cartridge 131, and the ratio of the shortest distance D3 between the inner sidewall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 to the diameter D4 of the mixing rotor 134 is in the range of about 1:1500 to about 1:4500, and the molding material prepared by the extrusion system 110 may be uniform and homogenized. In some embodiments, the molding material may be divided into multiple parts, and the ratio of polymer material to foaming agent in each part of the molding material prepared by the extrusion system 110 is substantially constant. In some embodiments, the ratio of polymer material to foaming agent in the first part of the molding material is substantially equal to the ratio of polymer material to foaming agent in the second part of the molding material. In some embodiments, the shortest distance D3 between the inner sidewall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 is substantially 0.3 mm or less. In some embodiments, the shortest distance D3 between the inner side wall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 is in the range of 0.01 to 0.09 mm.

[0023] Figure 2A is an enlarged view of a portion of an extrusion system according to an aspect of the present disclosure in several embodiments. In some embodiments, with reference to Figures 2 and 2A, the mixing rotor 134 further includes a cylindrical columnar body 1341 rotatably disposed within the mixing cartridge 131 and a grooved portion 1342 annularly arranged around the columnar body 1341, so as to enable uniform mixing of the molten polymer material and the foaming agent in the mixing cartridge 131, the mixing rotor 1344 further includes a cylindrical columnar body 1341 rotatably disposed within the mixing cartridge 131 and a grooved portion 1342 annularly arranged around the columnar body 1341. Thus, as the columnar body 1341 rotates, the polymer material and the foaming agent are agitated by the grooved portion 1342 to achieve the desired mixing effect. In some embodiments, the shortest distance D3 is the shortest distance between the grooved portion 1342 and the inner side wall 1311 of the hollow mixing cartridge 131. In some embodiments, when the shortest distance D3 is the shortest distance between the grooved portion 1342 and the inner side wall 1311 of the hollow mixing cartridge 131, the shortest distance D3 is in the range of 0.01 to 0.09 mm. In some embodiments, the diameter D4 of the mixing rotor 134 is in the range of 45 to 75 mm.

[0024] In some embodiments, when the shortest distance D3 is substantially less than 0.01 mm, the amount of foaming agent in a given amount of molding material is substantially 0.8 / cm 3 It exceeds 0.8 / cm³. In some embodiments, the amount of foaming agent in a predetermined amount of molding material is 0.8 / cm³. 3 If it substantially exceeds this, the bubble density in a predetermined amount of molding material after foaming is 180,000 / cm³. 3 It effectively exceeds that.

[0025] In some embodiments, the uniformity of the foaming agent to the polymer material is optimized when the ratio of the shortest distance D3 to the diameter D4 is in the range of 1:1500 to 1:4500. In other words, the mixing of the foaming agent and the polymer material by the mixing rotor 134 is uniform and homogenized. In some embodiments, when the ratio of the shortest distance D3 to the diameter D4 is in the range of 1:1500 to 1:4500, the ratio of foaming agent to polymer material in a predetermined amount of molding material is in the range of 4:1 to 3:1. In some embodiments, the ratio of foaming agent to polymer material in a predetermined amount of molding material is about 1:1. In some embodiments, when the ratio of foaming agent to polymer material in a predetermined amount of molding material is in the range of 4:1 to 3:1, the ratio of bubbles to polymer material in a predetermined amount of molding material after foaming is also in the range of 4:1 to 3:1. In some embodiments, the ratio of bubbles to polymer material in a predetermined amount of molding material after foaming is in the range of about 4:1.

[0026] In some embodiments, the melting unit 120 is configured to contain the polymer material and includes a hollow pressing cartridge 121 having a first pressure, and the mixing unit 130 includes a hollow mixing cartridge 131 having a second pressure. In some embodiments, the first pressure is greater than the second pressure to prevent backflow. In some embodiments, the polymer material is drawn from the melting unit 120 towards the mixing unit 130 by the difference between the first and second pressures.

[0027] The foaming agent supply unit 140 is connected to the mixing unit 130 and delivers the foaming agent to the mixing unit 130. In some embodiments, the foaming agent supply unit 140 is located between the first flow control element 161 and the second flow control element 162. In some embodiments, the foaming agent supply unit 140 is located proximal to the first flow control element 161 and distal to the second flow control element 162.

[0028] In some embodiments, a foaming agent source (not shown) is connected to a foaming agent supply unit 140 and configured to supply any type of foaming agent known to those skilled in the art. In some embodiments, the foaming agent is in a supercritical fluid state after being introduced into a mixing unit 130 by the foaming agent supply unit 140.

[0029] In some embodiments, a first flow control element 161 is located at a first port 171 connecting a melting unit 120 to a mixing unit 130. The first port 171 is configured to introduce polymer material from the melting unit 120 to the mixing unit 130. The first port 171 is located between the melting unit 120 and the mixing unit 130. In some embodiments, the first port 171 is configured to introduce polymer material from the pressing cartridge 121 of the melting unit 120 to the mixing cartridge 131 of the mixing unit 130. In some embodiments, the polymer material can be transported and / or drawn in from the melting unit 120 to the mixing unit 130 through the first port 171 by a pressure difference between a first pressure and a second pressure.

[0030] In some embodiments, the first flow control element 161 is positioned between the melting unit 120 and the mixing unit 130 and is configured to control the flow of polymer material from the melting unit 120 to the mixing unit 130. The first flow control element 161 may be a valve, a movable cover, or the like.

[0031] In some embodiments, the first flow control element 161 is configured to switch between an open configuration and a closed configuration. The open configuration of the first flow control element 161 allows polymer material to flow from the melting unit 120 into the mixing unit 130, while the closed configuration of the first flow control element 161 prevents polymer material from flowing back from the mixing unit 130 into the melting unit 120.

[0032] In some embodiments, the first flow control element 161 is configured to maintain a pressure difference between the melting unit 120 and the mixing unit 130. In some embodiments, the first flow control element 161 is configured to maintain a pressure difference between the melting unit 120 and the mixing unit 130 by switching between an open configuration and a closed configuration so that polymer material cannot flow back from the mixing cartridge 131 of the mixing unit 130 to the pressing cartridge 121 of the melting unit 120. In some embodiments, the first flow control element 161 is configured to adjust the first pressure and / or the second pressure in order to maintain a pressure difference between the first pressure and the second pressure. In some embodiments, the first flow control element 161 is in a closed configuration when the first pressure is equal to the second pressure.

[0033] In some embodiments, the injection unit 150 is configured to receive the molding material discharged from the second discharge passage 133 of the mixing unit 130 and to discharge the molding material from the injection unit 150. In some embodiments, the injection unit 150 is configured to inject the molding material, and the discharge channel 111 is in communication with the injection unit 150.

[0034] In some embodiments, the injection unit 150 includes a hollow metering cartridge 151 configured to contain a molding material. The metering cartridge 151 has a hollow internal space 1511, which communicates with a second discharge passage 133 and is configured to contain the molding material. The injection unit 150 further includes a connecting passage 152 communicating with the internal space 1511 of the metering cartridge 151, and a discharge member 153 slidably positioned in the internal space 1511 of the metering cartridge 151 and configured to discharge the molding material from the metering cartridge 151 through an outlet 154.

[0035] Referring again to Figure 1, in some embodiments, the injection unit 150 is configured to discharge the molding material into the molding apparatus 100 through a discharge channel 111 corresponding to one of the extrusion systems 110. In some embodiments, the discharge channel 111 communicating with the injection unit 150 is engageable with the molding apparatus 100 and is configured to discharge the molding material into the mold cavity 103 of the molding apparatus 100. The molding material flows from the extrusion system 110 into the discharge channel 111.

[0036] In some embodiments, the discharge channel 111 has an outlet 111o located away from the injection unit 150. The discharge channel 111 can be moved, extended, or retracted from the molding apparatus 100. In some embodiments, the outlet 111o of the discharge channel 111 may extend into the molding apparatus 111 and retract from there. The molding apparatus 100 includes a mold cavity 103 and a supply port 104 that is communicable with the mold cavity 103 and correspondingly engageable with the outlet 111o.

[0037] In some embodiments, the molding apparatus 100 includes a first mold 101 and a second mold 102. The first mold 101 is engageable with the second mold 102. The molding apparatus 100 is in a closed configuration when the first mold 101 engages with the second mold 102. In some embodiments, the first mold 101 is the lower mold and the second mold 102 is the upper mold, with the first mold 101 located below the second mold 102. In some embodiments, when the first mold 101 engages with the second mold 102, the mold cavity 103 of the molding apparatus 100 is defined by the first mold 101 and the second mold 102. The mold cavity 103 is configured to hold a molding material or a foamed member formed from the molding material.

[0038] In some embodiments, the supply port 104 is engageable with the outlet 111o. The supply port 104 is located in the first mold 101 or the second mold 102. In some embodiments, as shown in Figure 1, the supply port 104 is located on the side of the molding apparatus 100. In some embodiments, the supply port 104 is located in the first side wall 101s of the first mold 101 or the second side wall 102s of the second mold 102. The supply port 104 is configured to receive molding material from the discharge channel 111 of the injection unit 150 when the discharge channel 111 engages with the molding apparatus 100. The molding material can flow into the mold cavity 103 through the supply port 104. In some embodiments, the supply port 104 allows the molding material to flow at a predetermined flow rate.

[0039] In some embodiments, the injection molding system 200 includes a support device 114 configured to fix the discharge channel 111 to the molding apparatus 100. In some embodiments, the support device 114 includes a first element 1141 and a second element 1142. In some embodiments, the first element 1141 protrudes from the extrusion system 110, and the second element 1142 is positioned on the molding apparatus 100.

[0040] The molding apparatus 100 further includes one or more pressure regulating systems 106. In some embodiments, the molding apparatus 100 may include a different number of pressure regulating systems 106, or it may not include any pressure regulating systems 106. In some embodiments, the joint 107 is connected to the mold cavity 103. In some embodiments, the interior sidewall 105a or interior bottom wall 105b of the mold cavity 103 includes the joint 107. In some embodiments, the joint 107 is configured to allow a fluid or gas to enter or exit the mold cavity 103.

[0041] The pressure regulating system 106 may include a first gas conduit 1061, a second gas conduit 1062, a gas source 1063, a first valve 1064, a second valve 1065, and a pressure sensing unit 1066. In some embodiments, one end of the first gas conduit 1061 is connected to the inner side wall 105a or the inner bottom wall 105b of the molding apparatus 100. In some embodiments, one end of the first gas conduit 1061 is connected to a joint 107, and the other end of the first gas conduit 1061 is connected to the gas source 1063. In some embodiments, the gas source 1063 is configured to supply a fluid or gas, and may supply an appropriate fluid or gas as needed, for example, the fluid or gas may be air, an inert gas, etc., but the present invention is not limited to these.

[0042] The position, shape, and number of the joints 107 are not particularly limited and may be adjusted as needed. In some embodiments, the joints 107 are holes. In some embodiments, the joints 107 are located in the inner side wall 105a or the inner bottom wall 105b of the molding apparatus 100 and penetrate the first mold 101. In some embodiments, the joints 107 are configured to supply and release gas, and when the first valve 1064 is opened and the second valve 1065 is closed, fluid or gas is supplied to the mold cavity 103, and when the first valve 1064 is closed and the second valve 1065 is opened, at least a portion of the fluid or gas in the mold cavity 103 is released.

[0043] In some embodiments, the supply port 104 is located on the inner side wall 105a of the molding apparatus 100. In some embodiments, the supply port 104 and the joining point 107 are located on opposite sides of the mold cavity 103, and, as an example but not limited, the supply port 104 is located on one side of the inner side wall 105a and the joining point 107 is located on the opposite side of the inner side wall 105a. In some embodiments, the supply port 104 is located away from the joining point 107.

[0044] A first valve 1064 is located in the first gas conduit 1061 and is configured to control whether gas from the gas source 1063 enters the mold cavity 103 through the first gas conduit 1061 and the junction 107. A second gas conduit 1062 is coupled to the mold and communicates with the mold cavity 103. In some embodiments, the second gas conduit 1062 is coupled to the junction 107. A second valve 1065 is located in the second gas conduit 1062 and is configured to control whether gas from the mold cavity 103 is released through the second gas conduit 1062 and the junction 107.

[0045] In some embodiments, the second gas conduit 1062 is connected to the first gas conduit 1061 and the joint 107. In some embodiments, one end of the second gas conduit 1062 communicates with a space having a lower pressure than the pressure inside the mold cavity 103, for example, the external environment or a negative pressure space, but the present invention is not limited thereto. The location where the second gas conduit 1062 connects to the first gas conduit 1061 is not particularly limited, and may be connected, for example, at an end adjacent to the end of the first gas conduit 1061 that connects to the joint 107. In some embodiments, the first valve 1064 and the second valve 1065 do not open simultaneously.

[0046] The pressure sensing unit 1066 is configured to sense the pressure within the mold cavity 103. In some embodiments, the properties of the foamed polymer are influenced by the pore size and distribution across the polymer, which are related to temperature, pressure, and supply rate. The pressure sensing unit 1066 is not particularly limited as long as it can sense the pressure and provide pressure information after sensing the pressure within the mold cavity 103. The pressure adjustment system 106 modifies the conditions under which gas enters and leaves the mold cavity 103 according to the pressure information in order to adjust the pressure within the mold cavity 103 so that the resulting foamed polymer article has a desired predetermined shape and properties.

[0047] In some embodiments, the pressure sensing unit 1066 is located within the mold cavity 103, the first gas conduit 1061, or the second gas conduit 1062. In some embodiments, the pressure sensing unit 1066 is located within the mold cavity 103, away from the supply port 104. In some embodiments, the pressure regulating system 106 has a plurality of pressure sensing units 1066. The number and location of the plurality of pressure sensing units 1066 are not particularly limited and, for example, they may be located on the inner side walls of the mold cavity 103, spaced apart from each other, and / or at any location in the first gas conduit 1061, and / or at any location in the second gas conduit 1062, but the present invention is not limited thereto.

[0048] In some embodiments, the injection molding system 200 further includes a control system 109. The control system 109 is configured to control the extrusion system 110, the discharge channel 111, and the molding apparatus 100. In some embodiments, the control system 109 automatically controls the extrusion system 110, the discharge channel 111, and the molding apparatus 100 in real time. In some embodiments, the control system 109 controls the pressure adjustment system 106 in real time.

[0049] In some embodiments, the control system 109 includes a central processor 1091 and a plurality of sensors 1092 electrically connected to or communicable with the central processor 1091. In some embodiments, the sensors 1092 are positioned throughout the injection molding system 200 and are configured to sense at least one processing condition (e.g., flow rate or viscosity of the molding material through the discharge channel 20, amount of molding material discharged from the discharge channel 111, pressure in the mold cavity 103, etc.) at a given location in the injection molding system 200 (e.g., extrusion sequence to the molding apparatus 100, alignment of the discharge channel 111 with the molding apparatus 100, outlet 111o, supply port 104, mold cavity 103, etc.). In some embodiments, the sensors 1092 are configured to detect the processing condition and transmit signals or data based on the detected processing condition to the central processor 1091 for further analysis.

[0050] In some embodiments, the control system 109 controls which molding apparatus 100 the discharge channel 111 is docked to. In some embodiments, the cable 1093 is electrically connected between the control system 109 and the extrusion system 110, the discharge channel 111, and the molding apparatus 100. The cable 1093 is configured to transmit signals from the molding apparatus 100 to the extrusion system 110 and the discharge channel 111.

[0051] In some embodiments, the control system 109 is configured to process pressure information detected by the pressure sensing unit 1066 and to adjust the mixing conditions of the extrusion system 110 and the extrusion amount and timing of the discharge channel 111. In some embodiments, the pressure sensing unit 1066 provides pressure information to the control system 109, which adjusts the first valve 1064 and the second valve 1065 according to the pressure information. In some embodiments, the control system 109 adjusts the conditions under which gas enters / exits the mold cavity 103 in real time according to the pressure information, and adjusts the timing and amount of molding material injected from the discharge channel 111 into the mold cavity 103 so that the amount and rate of injection during the injection molding process are appropriate or within a predetermined range, so that the pressure in the mold cavity 103 is always appropriate or within a predetermined pressure range. In some embodiments, the control system 109 further controls the supply conditions of the supply port 104 and the gas supply conditions of the gas source 1063. In some embodiments, the control system 109, the first valve 1064, the second valve 1065, the pressure sensing unit 1066, and the supply port 104 are electrically connected.

[0052] Figure 3 is a schematic diagram of an injection molding system 300 according to one embodiment of the present invention. The injection molding system 300 includes an extrusion system 110 having an injection unit 150 and a molding apparatus 100, as shown in Figure 3. In some embodiments, a supply port 104 is located between a first mold 101 and a second mold 102. In some embodiments, the supply port 104 includes a first partial port 104a in the first mold 101 and a second partial port 104b in the second mold 102, wherein the first partial port 104a is aligned with the second partial port 104b when the molding apparatus 100 is in a closed configuration. In some embodiments, the first partial port 104a is configured as a recess in the first side wall 101s of the first mold 101, and the second partial port 104b is configured as a recess in the second side wall 102s of the second mold 102.

[0053] This disclosure discloses a method for manufacturing articles. In some embodiments, injection molding is performed by the method. The method includes several operations, and the description and examples are not intended to limit the sequence of operations. Figure 4 is a flowchart of an injection molding method according to one embodiment of the present invention. In some embodiments, as shown in Figure 4, a method for manufacturing the article 119 shown in Figures 16 and 17 includes the following steps.

[0054] Step 401 includes providing a molding apparatus having a first mold and a second mold. Step 402 includes arranging a component between the first mold and the second mold, the component including a hollow space and an opening communicating with the hollow space. Step 403 includes engaging the opening with either the first mold or the second mold. Step 404 includes engaging the first mold with the second mold to form a mold cavity surrounding the component, the opening engaging with a supply port of the molding apparatus that communicates with the hollow space.

[0055] Step 405 includes injecting a molding material into the hollow space through a supply port and opening, the molding material comprising a polymer material and a foaming agent. Step 406 includes foaming the molding material to form a foamed member. In some embodiments, the supply port is located on the side wall of the molding apparatus. In some embodiments, the foamed member is in contact with the inner surface 112c of the part. In some embodiments, the hollow space expands within the mold cavity during the formation of the foamed member.

[0056] Method 400 is not limited to the embodiments described above. In some embodiments, the method for manufacturing the article 119 shown in Figures 16 and 17 uses one of the injection molding systems 200, 300 described above, as shown in Figures 1 to 3.

[0057] Figures 5A and 5B are flowcharts showing an injection molding method according to one embodiment of the present invention. In some embodiments, as shown in Figures 5A and 5B, the method 500 for manufacturing an article includes the following steps.

[0058] Methods for manufacturing articles are disclosed according to several embodiments of this disclosure. In some embodiments, the injection molding systems 200 and 300 described above, as shown in Figures 1 to 3, are used by Method 500. Figures 5A and 5B are flowcharts of Method 500 according to some embodiments. Method 500 comprises several operations (501 to 512), and the description and examples are not intended to limit the sequence of operations. Additional steps may be provided before, between, and after the operations shown in Figures 5A and 5B, and in other embodiments of Method 500, some of the operations described below may be replaced or omitted. The order of operations may be interchangeable.

[0059] Figures 6-8 and 11-15 are schematic cross-sectional views of one or more operations of Method 500 for manufacturing articles according to some embodiments of the present disclosure. Figure 10 is a schematic diagram of a portion of an injection molding system according to one embodiment of the present disclosure. Figures 16 and 17 are schematic cross-sectional views showing an article 119 manufactured by Method 500 according to some embodiments of the present disclosure. Method 500 begins with operation 501. Operation 501 includes providing an extrusion system 110 having a melting unit 120 and a mixing unit 130, as shown in Figure 2, configured to produce a molding material 113' as shown in Figure 12. Method 500 proceeds to operation 502. Operation 502 includes providing an exhaust channel 111, which is communicable with the extrusion system 110, located distal to the extrusion system 110, and includes an outlet 111o configured to discharge the molding material 113'.

[0060] Method 500 proceeds to operation 503, which includes providing a molding apparatus 100 having a first mold 101 and a second mold 102. In some embodiments, operation 503 of Method 500 is similar to operation 401 of Method 400.

[0061] In some embodiments, referring to Figure 6, the molding apparatus 100 includes a second mold 102 and a first mold 101 opposite the second mold 102. In some embodiments, the second mold 102 is the upper mold and the first mold 101 is the lower mold. In some embodiments, the second mold 102 and the first mold 101 are separated from each other. In some embodiments, the second mold 102 and the first mold 101 may be aligned and complementary to each other and separable from each other. In some embodiments, the first mold 101 or the second mold 102 includes a supply port 104. In some embodiments, the supply port 104 is located on the first side wall 101s of the first mold 101 or on the second side wall 102s of the second mold 102.

[0062] Method 500 proceeds to operations 504 and 505. Operation 504 includes positioning a component 112 between a first mold 101 and a second mold 102, the component 112 having a hollow space 112a and an opening 112b communicating with the hollow space 112a. Operation 505 includes engaging the opening 112b with the first mold 101 or the second mold 102. In some embodiments, operations 504 and 505 of Method 500 are similar to operations 402 and 403 of Method 400.

[0063] Referring to Figure 7, part 112 is placed in either the first mold 101 or the second mold 102. In some embodiments, part 112 is placed in the first partial mold cavity 103a of the first mold 101 and is in at least partial contact with the first mold 101. In some embodiments, part 112 is in contact with one or more of the inner side walls 105a of the first mold 101. In some embodiments, the second mold 102 has a second partial mold cavity 103b corresponding to the first partial mold cavity 103a.

[0064] In some embodiments, the component 112 is flexible, elastic, or resilient. In some embodiments, the component 112 is cloth, fabric, woven fabric, etc. In some embodiments, the component 112 is breathable.

[0065] Method 500 proceeds to operation 506. Operation 506 involves engaging the first mold 101 with the second mold 102 to form a mold cavity 103 surrounding the part 112, the opening 112b engaging with a supply port 104 of the molding apparatus 100 which is in communication with the hollow space 112a. In some embodiments, operation 506 of Method 500 is similar to operation 404 of Method 400. In some embodiments, the supply port 104 is located on the inner side wall 105a of the molding apparatus 100.

[0066] In some embodiments, referring to Figure 8, the mold cavity 103 is defined when the second mold 102 and the first mold 101 are aligned and complementary to each other. The mold cavity 103 may be defined by the first mold cavity 103a of the first mold 101 and the second mold cavity 103b of the second mold 102. In some embodiments, the inner side wall 105a of the molding apparatus 100 is curved. In some embodiments, the inner side wall 105a of the molding apparatus 100 is a curved surface including a concave surface, a convex surface, or a combination of a concave and a convex surface. In some embodiments, the opening 112b and the portion of part 112 adjacent to the opening 112b are positioned within the supply port 104 when the opening 112b engages with the supply port 104, and the portion of part 112 is inserted into the supply port 104. Component 112 is positioned in the first mold 101 and / or the second mold 102 when the opening 112b engages with the supply port 104. As a result, the supply port 104 can communicate with the hollow space 112a when the opening 112b engages with the supply port 104.

[0067] After placing part 112 in the first mold 101 or the second mold 102, the first mold 101 is engaged with the second mold 102, as shown in Figure 8. The molding apparatus 100 is in a closed configuration when the first mold 101 is engaged with the second mold 102. The first partial mold cavity 103a and the second partial mold cavity 103b combine to form the mold cavity 103 when the first mold 101 is engaged with the second mold 102. Part 112 is sealed inside the mold cavity 103 by the molding apparatus 100.

[0068] Method 500 proceeds to operation 507, which includes engaging the discharge channel 111 with the supply port 104 before or after engaging the first mold 101 and the second mold 102.

[0069] Returning to Figure 7, the extrusion system 110 and the discharge channel 111 are located away from the molding apparatus 100. In some embodiments, the discharge channel 111 is moved to a first position adjacent to the molding apparatus 100 before the outlet 111o engages with the supply port 104 of the molding apparatus 100. In some embodiments, the discharge channel 111 is moved to a first position adjacent to the molding apparatus 100. In the first position, the discharge channel 111 is aligned with the supply port 104 of the molding apparatus 100. In some embodiments, the distance between the outlet 111o and the supply port 104 is greater than 0. In some embodiments, in the first position, the discharge channel 111 is aligned with the supply port 104.

[0070] In some embodiments, referring to Figure 8, after the discharge channel 111 is aligned with the supply port 104, the discharge channel 111 is moved toward the molding apparatus 100 so that it is received by the supply port 104, and then the outlet 111o is docked with the supply port 104. In some embodiments, the discharge channel 111 is moved toward the molding apparatus 100 so that it is received by the supply port 104. In some embodiments, the discharge channel 111 is moved toward the molding apparatus 100 so that it is received by the supply port 104.

[0071] In some embodiments, the discharge channel 111 engages with the supply port 104 before or after engaging the first mold 101 and the second mold 102. After the outlet 111o docks with the supply port 104, the outlet 111o and the supply port 104 form a flow path for the molding material 113', and as a result, the discharge channel 111 communicates with the hollow space 112a through the discharge port 104 and the opening 112b. In some embodiments, the discharge channel 111 partially protrudes into the supply port 104 when the discharge channel 111 is engaged with the supply port 104. In some embodiments, the opening 112b and the portion of part 112 adjacent to the opening 112b are located within the supply port 104 when the opening 112b is engaged with the supply port 104.

[0072] The outlet 111o must be securely engaged with the supply port 104 to prevent the molding material 113' from leaking out of the molding apparatus 100. In some embodiments, method 500 includes fixing the discharge channel 111 to the molding apparatus 100. In some embodiments, force is provided by a support device 114 to prevent the extrusion system 110 from separating from the molding apparatus 100.

[0073] In some embodiments, when the extrusion system 110 injects the molding material 113' into the molding apparatus 100, the molding apparatus 100 may generate a reaction force opposite to the injection direction, which may be transmitted to the discharge channel 111 and the extrusion system 110, resulting in the discharge channel 111 tending to separate from the molding apparatus 100. In some embodiments, a support device 114 provides support against the reaction force opposite to the injection direction.

[0074] In some embodiments, the discharge channel 111 is fixed to the molding apparatus 100 by engaging a first element 1141 of the support device 114 with a second element 1142 of the support device 114, thereby fixing the discharge channel 111 to the molding apparatus 100, with the first element 1141 protruding from the extrusion system 110 and the second element 1142 positioned on the molding apparatus 100. In some embodiments, after engagement, force is provided by the support device 114 to prevent the discharge channel 111 from separating from the molding apparatus 100.

[0075] Figure 9 is a schematic diagram of a portion of an injection molding system 200 according to one embodiment of the present disclosure. In some embodiments, referring to Figure 9, the support device 114 includes a first element 1141 and a second element 1142 configured to engage with each other, the first element 1141 protruding from an extrusion system 110 or discharge channel 111, and the second element 1142 positioned on a molding apparatus 100, but the present disclosure is not limited thereto. In some embodiments, the first element 1141 and the second element 1142 can be clamped to each other, for example, the second element 1142 is configured to receive the first element 1141.

[0076] In some embodiments, the support device 114 is positioned adjacent to the mold cavity 103 of the molding apparatus 100. In some embodiments, the first element 1141 is positioned on the discharge channel 111, and the second element 1142 is positioned on the molding apparatus 100. In some embodiments, the first element 1141 is part of the extrusion system 110 or the discharge channel 111, and the second element 1142 is part of the molding apparatus 100. In some embodiments, the first element 1141 is part of the extrusion system 110 and is positioned adjacent to the discharge channel 111. In some embodiments, the first element 1141 and the second element 1142 engage with each other, thereby allowing the discharge channel 111 to be firmly engaged with the molding apparatus 100.

[0077] In some embodiments, to prevent the extrusion system 110 and the molding apparatus 100 from separating during injection, the engaged first element 1141 is subjected to a force resisting the second element 1142. This force may be greater than or equal to a threshold. The threshold may be adjusted according to the pressure in the mold cavity 103 and the hollow space 112a and the diameter of the outlet 111o, or according to other factors.

[0078] The position and number of the first elements 1141 may be adjusted as needed and are not particularly limited. The position and number of the second elements 1142 may also be adjusted as needed and are not particularly limited. In some embodiments, the position and number of the second elements 1142 correspond to the position and number of the first elements 1141. In one embodiment, the first elements 1141 can be positioned at any suitable location on or adjacent to the discharge channel 111, and the second elements 1142 can be positioned at any suitable location on the molding apparatus 100.

[0079] Figure 10 is a schematic diagram of a portion of an injection molding system 200 according to one embodiment of the present invention. In some embodiments, referring to Figure 10, the support device 114 can be in one of two states: locked or unlocked. In the unlocked state, the first element 1141 enters the corresponding second element 1142 but is not yet locked to the second element 1142. In other words, the first element 1141 can still be pulled out of the second element 1142 when the support device 114 is in the unlocked state. In the locked state, the first element 1141 enters the corresponding second element 1142 and locks with it so that the first element 1141 cannot be pulled out of the second element 1142. Figure 10 shows the support device 114 in the locked state. The support device 114 can be operated and controlled manually or automatically. The support device 114 can be switched between the two states manually or automatically.

[0080] In some embodiments, the first element 1141 is rotatably fixed to the extrusion system 110. In some embodiments, the first element 1141 includes a long portion 1143 and an arm portion 1144. The long portion 1143 and the arm portion 1144 are rotatable in the direction of arrow A. The long portion 1143 is fixed to the extrusion system 110 and extends in a first direction Z toward the second mold 102. The arm portion 1144 is connected to the long portion 1143 and extends in a second direction X substantially perpendicular to the first direction Z or a third direction Y substantially perpendicular to the first direction Z. In some embodiments, the first element 1141 has an inverted T shape. After the first element 1141 enters the second element 1142, the support device 114 changes from an unlocked state to a locked state by the rotation of the arm portion 1144 of the first element 1141. In some embodiments, the first element 1141 is locked with the second element 1142 by rotating the arm portion 1144 of the first element 1141 by about 90 degrees. Figure 10 shows that after the arm portion 1144 has been rotated by about 90 degrees, the arm portion 1144 is locked with the second element 1142. As a result, the support device 114 is in a locked state, and the discharge channel 111 is firmly engaged with the molding device 100, and thus the injection of molding material 113' from the extrusion system 110 and the discharge channel 111 into the molding device 100 can begin.

[0081] In some embodiments, referring to Figures 8 to 10, the discharge channel 111 is fixed to the molding apparatus 100 by rotating the support device 114 in a locked state, such as by rotating the first element 1141 of the support device 114 relative to and within the second element 1142 of the support device 114, while engaging the outlet 111o with the supply port 114. In some embodiments, when the outlet 111o is docked with the supply port 114, the first element 1141 enters the second element 1142 and is then locked with the second element 1142. In some embodiments, the discharge channel 111 is fixed to the molding apparatus 100 by rotating the elongated portion 1143 and the arm portion 1144 of the first element 1141 of the support device 114, the elongated portion 1143 being fixed to the extrusion system 110 and extending toward the molding apparatus 100 in a first direction Z, and the arm portion 1144 being coupled to the elongated portion 1143 and extending in a second direction X different from the first direction Z.

[0082] In some embodiments, referring to Figure 11, method 500 further includes injecting gas G into the mold cavity 103 and / or hollow space 112a after engaging the first mold 101 and the second mold 102 to increase the pressure within the mold cavity 103 and / or hollow space 112a. In some embodiments, the gas is used to form the molding material. 113’ of Hollow space 112a Before injection, the gas G is injected through a pressure regulating system 106 associated with the mold cavity 103 until it is sensed that the mold cavity 103 has a first predetermined pressure. In some embodiments, the gas G is injected into the mold cavity 103 through a first gas conduit 1061. In some embodiments, the gas G is any suitable gas as needed, for example, air, but the present invention is not limited thereto. In some embodiments, after the outlet 111o and the supply port 114 are engaged, the pressure in the mold cavity 103 of the molding apparatus 100 is adjusted to a first predetermined pressure. After the molding apparatus 100 has reached the first predetermined pressure, injection is started. In some embodiments, the gas G is air, etc.

[0083] In some embodiments, a pressure sensing unit 1066 senses that the pressure in the mold cavity 103 is atmospheric pressure. In some embodiments, a first valve 1064 is opened so that gas G is injected into the mold cavity 103 through a first gas conduit 1061. In some embodiments, gas G is injected into the mold cavity 103 through a pressure regulating system 106 when the supply port 114 is closed. In some embodiments, gas G is injected into the mold cavity 103 through the supply port 104.

[0084] In some embodiments, the pressure inside the mold cavity 103 is continuously sensed during the process of injecting gas G into the mold cavity 103. In some embodiments, a pressure sensing unit 1066 continuously senses the pressure inside the mold cavity 103 and injects gas G into the mold cavity 103 until it senses that the mold cavity 103 has reached a first predetermined pressure, and then closes the first valve 1064 and the second valve 1065 of the pressure regulating system 106 to stop injecting gas G into the mold cavity 103. In some embodiments, the first predetermined pressure is higher than atmospheric pressure. In some embodiments, the first predetermined pressure is lower than atmospheric pressure.

[0085] In some embodiments, before operation 508, the mold cavity 103 reaches a first predetermined pressure, and the first valve 1064 and the second valve 1065 of the pressure regulating system 106 are closed.

[0086] In some embodiments, method 500 includes operation 508, which involves injecting a molding material 113' from an extrusion system 110 into a hollow space 112a through a supply port 104 and an opening 112b, the molding material 113' comprising a polymer material and a foaming agent. Several implementations

[0087] In some embodiments, the molding material 113' is produced by an extrusion system 110, and the molding material 113' is discharged from an injection unit 150 and flows into the hollow space 112a of the part 112 through an outlet channel 111, a supply port 104, and an opening 112b. In some embodiments, referring to Figure 12, the molding material 113' is injected into the mold cavity 103 through an outlet 111o and a supply port 104. In some embodiments, the discharge channel 111 is at least partially surrounded by the molding apparatus 100 once the molding material 113' is injected.

[0088] In some embodiments, a single shot of molding material 113' is injected to fill the entire hollow space 112a. Because part 112 is elastic, part 112 and the hollow space 112a may expand during or after the injection of molding material 113' into the hollow space 112a. The volume of the hollow space 112a increases during or after the injection of molding material 113'. In some embodiments, after the injection of molding material 113' into the hollow space 112a, the hollow space 112a continues to expand as the molding material 113' undergoes physical foaming within the hollow space 112a.

[0089] In some embodiments, during the process of injecting the molding material 113' into the hollow space 112a in operation 508, the pressure in the mold cavity 103 changes rapidly, and the pressure sensing unit 1066 continuously senses the pressure in the mold cavity 103. In some embodiments, the molding material 113' is injected into the hollow space 112a from the supply port 104, and a first predetermined pressure is applied to the molding material 113'. In some embodiments, the molding material 113' and gas G are placed in the mold cavity 103 or the hollow space 112a, and the molding material 113' expands and foams in the hollow space 112a.

[0090] In some embodiments, the molding material 113' is injected into the hollow space 112a through the supply port 104 and the opening 112b, increasing the pressure within the mold cavity 103. In some embodiments, the pressure within the mold cavity 103 of the molding apparatus 100 rises above a first predetermined pressure. In some embodiments, the pressure within the mold cavity 103 of the molding apparatus 100 rises from a first predetermined pressure to a second predetermined pressure.

[0091] In some embodiments, after the molding material 113' is injected into the hollow space 112a within the mold cavity 103 having a first predetermined pressure, the pressure in the mold cavity 103 increases, so setting a second predetermined pressure ensures that the mold cavity 103 is maintained within an appropriate pressure range. In some embodiments, when the mold cavity 103 reaches the second predetermined pressure, the injection of the molding material 113' into the hollow space 112a is stopped.

[0092] In some embodiments, the process of injecting molding material 113' into the hollow space 112a within the mold cavity 103 having a first predetermined pressure lasts for less than 3 seconds. In some embodiments, because the mold cavity 103 has a first predetermined pressure, the completion of filling with molding material 113' may last for less than 0.5 seconds. During the injection period or at the moment of injection completion, the pressure within the mold cavity 103 is sensed in real time by the pressure sensing unit 1066 and pressure information is provided so that the pressure adjustment system 106 can adjust the pressure within the mold cavity 103 according to the pressure information, thereby maintaining the pressure within the mold cavity 103 within a predetermined pressure range. In some embodiments, during the injection process, the temperature of the discharge channel 111 is higher than the temperature of the molding apparatus 100. In some embodiments, force is applied to the first mold 101 and / or the second mold 102 during or after the injection of molding material 113' in order to maintain the mold cavity 103 or the hollow space 112a at a predetermined pressure level. In some embodiments, the pressure level is suitable for physical foaming.

[0093] In some embodiments, method 500 includes operations 509 and 510. Operation 509 includes foaming the molding material 113' to form a foamed member 113, which expands within the mold cavity 103 during its formation. Operation 510 includes expanding the part 112 during or after the injection of the molding material 113' into the hollow space 112a. In some embodiments, operation 509 of method 500 is similar to operation 406 of method 400.

[0094] In some embodiments, after the injection of the molding material 113', the molding material 113' undergoes physical foaming within the mold cavity 103 as shown in Figure 13, becoming the foamed member 113 as shown in Figure 14. Referring to Figures 13 and 14, the part 112 expands during the formation of the foamed member 113 until the part 112 contacts the inner wall 105 of the mold cavity. In some embodiments, the hollow space 112a expands until the part 112 is in full contact with the inner wall 105 of the mold cavity 103.

[0095] In some embodiments, during the physical foaming of the molding material 113' or after the formation of the foamed member 113, Method 500 further includes venting at least a portion of the gas G from the mold cavity 103 and / or the hollow space 112a. In some embodiments, a portion of the gas G is released from the mold cavity 103 after the gas G has been injected into the mold cavity 103. In some embodiments, during operations 509 and 510, the gas G is released from the mold cavity 103 through the pressure regulating system 106 in less than one second while the molding material 113' is foaming in the hollow space 112a or while the foamed member 113 is being formed. The release of a portion of the gas G may result in the molding material 113' in the mold cavity 103 having a lower density after the foaming process. In some embodiments, the gas G is released from the mold cavity 103 through the joint 107. In some embodiments, the pressure in the mold cavity 103 is reduced from a second predetermined pressure.

[0096] In some embodiments, the pressure in the mold cavity 103 and / or the hollow space 112a is reduced to a third predetermined pressure by releasing a portion of the gas G. The pressure in the mold cavity 103 or the hollow space 112a is reduced by releasing a portion of the gas G from the mold cavity 103 and / or the hollow space 112a, and / or by releasing a portion of the physical foaming agent released from the molding material 113' from the mold cavity 103 and / or the hollow space 112a.

[0097] In some embodiments, when the pressure sensing unit 1066 senses that the pressure in the mold cavity 103 is greater than a second predetermined pressure, a portion of the gas G in the mold cavity 103 is released until the pressure in the mold cavity 103 falls within a predetermined pressure range. In some embodiments, the predetermined pressure range is between a first predetermined pressure and a second predetermined pressure. In some embodiments, the second valve 1065 is open, and a portion of the gas G in the mold cavity 103 is discharged through a second gas conduit 1062.

[0098] In some embodiments, method 500 includes operation 511, which includes disengaging the first mold 101 and the second mold 102 after the foam member 113 has been formed.

[0099] In some embodiments, referring to Figure 15, after the foam member 113 is formed, the discharge channel 111 is disengaged from the supply port 104 before or after disengaging the first mold 101 and the second mold 102. The article 119, including the foam member 113 and the part 112, is formed in the mold cavity 103 as shown in Figure 14. The foam member 119 is in direct contact with the inner surface 112c of the part 112. The article 119 thus formed does not contain any adhesive.

[0100] The discharge port 111o is disconnected from the supply port 104. The molding apparatus 100 is changed from a closed configuration (Figures 8 and 11-14) to an open configuration.

[0101] In some embodiments, method 500 includes operation 512, which includes removing the article 119, including the parts 112 and the foamed member 113, from the molding apparatus 100.

[0102] In some embodiments, referring to Figure 16, the article 119 can be removed from the mold cavity 103 after the first mold 101 and the second mold 102 have been disengaged. In some embodiments, after the article 119 has been formed, the article 119 is then removed from the first mold 101. In some embodiments, the article 119 is removed manually by a human or automatically by a robot, robotic arm, gripper, etc.

[0103] In some embodiments, method 500 further includes trimming the sides of article 119. Referring to Figure 17, the sides of article 119 are trimmed so that the article 119 having the foam member 113 is positioned between a first portion 112d of part 112 and a second portion 112e of part 112 separated from the first portion 112d.

[0104] In some embodiments, the thickness of part 112 is substantially thinner than the thickness of the foam member 113. In some embodiments, the overall thickness T of article 119 is substantially less than 2 mm. In some embodiments, the overall thickness T of article 119 is substantially less than 1 mm. In some embodiments, the thickness of the foam member 113 is substantially less than 1 mm. In some embodiments, the thickness of the foam member 113 is substantially less than 0.5 mm. The foam member 113 is directly attached to the first part 112d and the second part 112e, with no additional parts or materials (such as adhesive) placed between them. In some embodiments, part 112 is softer than the foam member 113. In some embodiments, the foam member 113 has a density of about 0.05 to about 0.5.

[0105] In some embodiments, Method 500 includes the following operations. In some embodiments, the steps described below can be repeated and performed automatically. In some embodiments, the injection molding system 300 described above, as shown in Figure 3, is used by Method 500. Figures 18 to 24 are schematic cross-sectional views of one or more operations of Method 500 for manufacturing articles according to some embodiments of the present disclosure.

[0106] In some embodiments, in operation 503, the injection unit 150 and the molding apparatus 100 are initially provided as shown in Figure 18. The molding apparatus 100 is in an open configuration, with the discharge channel 111 disengaged from the supply port 104 and the first mold 101 disengaged from the second mold 102.

[0107] In some embodiments, the supply port 104 has a first partial port 104a on the first side wall 101s of the first mold 101 and a second partial port 104b on the second side wall 102s of the second mold 102. In some embodiments, the first partial port 104a and the second partial port 104b are separated from each other when the molding apparatus 100 is in an open configuration as shown in Figure 18.

[0108] In some embodiments, during operation 504, the part 112 is positioned between the first mold 101 and the second mold 102, as shown in Figure 19. In some embodiments, the opening 112b faces either the first partial port 104a or the second partial port 104b, and the opening 112b is engageable with the first partial port 104a and / or the second partial port 104b.

[0109] In some embodiments, in operation 505, referring to Figure 20, the supply port 104 is formed after the first mold 101 engages with the second mold 102. In some embodiments, the supply port is formed when the molding apparatus 100 is in a closed configuration. As a result, the supply port 104 is formed and the opening 112b engages with the supply port 104, communicating with the hollow space 112a. In some embodiments, the formation of the supply port 104 and the engagement of the opening 112b with the thus formed supply port 104 occur simultaneously.

[0110] In some embodiments, in operation 507, referring to Figure 21, the discharge channel 111 engages with the supply port 104 and comes into contact with the first mold 101 and the second mold 102. In some embodiments, before or after engaging the first mold 101 and the second mold 102, the discharge channel 111 engages with the supply port 104 in the same manner as described above or shown in Figure 11, as shown in Figure 20. In some embodiments, the discharge channel 111 is fixed to the molding apparatus 100. In some embodiments, after engaging the first mold 101 and the second mold 102, gas is injected into the mold cavity 103 and / or hollow space 112a to increase the pressure in the mold cavity 103 and / or hollow space 112a. In some embodiments, the gas G is air, etc. In some embodiments, force is applied to the first mold 101 and / or the second mold 102 during or after the injection of the mixture 113' in order to maintain the mold cavity 103 and / or hollow space 112a at a predetermined pressure level suitable for physical foaming.

[0111] In some embodiments, in operation 508, referring to Figures 21 and 22, after engaging the first mold 101 and the second mold 102, the molding material 113' is injected into the hollow space 112a in the same manner as described above or in Figures 12 and 13. In some embodiments, gas G is injected into the hollow space 112a or mold cavity 103 before the molding material 113' is injected into the hollow space 112a. The molding material 113' is discharged from the injection unit 150 and flows into the hollow space 112a of the part 112 through the discharge channel 111, the supply port 104 and the opening 112b. In some embodiments, a single shot of the mixture 113' is injected to fill the entire hollow space 112a.

[0112] In some embodiments, in operation 509, referring to Figures 22 and 23, after the molding material 113' is injected, the molding material 113' undergoes physical foaming in the molding cavity 103 in a manner similar to that described above or shown in Figures 13 and 14 to become a foamed member 113. In some embodiments, during the physical foaming of the molding material 113' or after the formation of the foamed member 113, the pressure in the mold cavity 103 and / or the hollow space 112a is reduced by releasing at least a portion of the gas G from the mold cavity 103 and / or the hollow space 112a, and / or releasing a portion of the physical foaming agent released from the molding material 113' from the mold cavity 103 and / or the hollow space 112a.

[0113] In some embodiments, in operation 510, still referring to Figures 22 and 23, since part 112 is elastic, the molding material 113' may expand during or after the injection of the molding material 113' into the hollow space 112a. The volume of the hollow space 112a increases during or after the injection of the molding material 113'. In some embodiments, the hollow space 112a expands until part 112 is in full contact with the inner wall 105 of the mold cavity 103, as shown in Figure 22. In some embodiments, after the injection of the mixture 113' into the hollow space 112a, the hollow space 112a continues to expand as the mixture 113' undergoes physical foaming within the hollow space 112a.

[0114] In some embodiments, in operation 510, referring to Figure 24, after the foam member 113 is formed in the mold cavity 103, the first mold 101 is disengaged from the second mold 102 in the same manner as described above or shown in Figure 15. In some embodiments, the discharge channel 111 is disengaged from the supply port 104 before or after the first mold 101 and the second mold 102 are disengaged. The article 119 thus formed is similar to that shown in Figure 16. In some embodiments, after the article 119 is removed from the mold cavity 103, the sides of the article 119 are trimmed as shown in Figure 17. As a result, an article 119 having the foam member 113 between the first portion 112d and the second portion 112e of part 112 is formed.

[0115] The above outlines some features of embodiments so that those skilled in the art may better understand aspects of the present disclosure. Those skilled in the art should understand that the present disclosure may be readily used as a basis for designing or modifying other processes and structures for the purpose of serving the same objectives and / or achieving the same advantages as the embodiments presented herein. Those skilled in the art should also recognize that such equivalent configurations will not depart from the spirit and scope of the present disclosure, and that they may be modified, replaced, and altered in various ways herein without departing from the spirit and scope of the present disclosure.

[0116] Furthermore, the scope of this application is not intended to be limited to specific embodiments of the processes, machines, manufactures, compositions, means, methods, and steps described herein. As will be readily apparent to those skilled in the art from the disclosure of the present invention, existing or subsequently developed processes, machines, manufactures, compositions, means, methods, or steps that perform substantially the same functions or achieve substantially the same results as the corresponding embodiments described herein can be utilized in accordance with the present invention. Accordingly, the appended claims are intended to include such processes, machines, manufactures, compositions, means, methods, and steps within their scope.

Claims

1. A method for manufacturing articles, The step of providing a molding apparatus having a first mold and a second mold, A step of arranging a component between the first mold and the second mold, wherein the component includes a hollow space and an opening communicating with the hollow space, The steps include engaging the opening with the first mold or the second mold, A step of engaging the first mold with the second mold to form a mold cavity surrounding the part, wherein the opening engages with a supply port of the molding apparatus that is in communication with the hollow space, A step of injecting a molding material into the hollow space through the supply port and the opening, wherein the molding material comprises a polymer material and a foaming agent, The steps include: forming a foamed member by foaming the aforementioned molding material; Includes, The foam member is in contact with the inner surface of the part, A method comprising: before injecting the molding material into the hollow space, injecting gas into the mold cavity surrounding the part to increase the pressure in the mold cavity to a first predetermined pressure; and stopping the injection of the molding material into the hollow space when the pressure in the mold cavity reaches a second predetermined pressure, wherein the second predetermined pressure is greater than the first predetermined pressure.

2. The step of expanding the part during or after the injection of the molding material into the hollow space. It further includes, The method according to claim 1, wherein the component expands until it contacts the inner side wall of the mold cavity.

3. The method according to claim 1, wherein the supply port is formed after the engagement of the first mold and the second mold.

4. The method according to claim 1, wherein the supply port is located on the first side wall of the first mold or on the second side wall of the second mold.

5. The method according to claim 1, wherein the supply port is located between the first mold and the second mold, and the supply port includes a first partial port in the first mold and a second partial port in the second mold, and the first partial port is aligned with the second partial port when the molding apparatus is in a closed configuration.

6. Before injecting the molding material, After the engagement of the first mold and the second mold, gas is injected into the hollow space to increase the pressure within the hollow space. The method according to claim 1, further comprising:

7. After injecting the molding material, Steps to discharge gas from the mold cavity or the hollow space to reduce the pressure inside the mold cavity or the hollow space. The method according to claim 1, further comprising:

8. A method for manufacturing articles, The step of providing a molding apparatus having a first mold and a second mold, A step of arranging a component between the first mold and the second mold, wherein the component includes a hollow space and an opening communicating with the hollow space, The steps include engaging the opening with the first mold or the second mold, A step of engaging the first mold with the second mold to form a mold cavity surrounding the part, wherein the opening engages with a supply port of the molding apparatus that is in communication with the hollow space, the supply port is located on the side wall of the molding apparatus, and the part is located within the mold cavity, The steps include injecting the molding material into the hollow space through the supply port and the opening, The steps include: forming a foamed member by foaming the aforementioned molding material; Includes, The aforementioned hollow space expands within the mold cavity during the formation of the foamed member. A method comprising: before injecting the molding material into the hollow space, injecting gas into the mold cavity surrounding the part to increase the pressure in the mold cavity to a first predetermined pressure; and stopping the injection of the molding material into the hollow space when the pressure in the mold cavity reaches a second predetermined pressure, wherein the second predetermined pressure is greater than the first predetermined pressure.

9. After forming the foamed member, the first mold and the second mold are disengaged. The steps of removing the article, including the aforementioned parts and the foamed member, from the molding apparatus. The method according to claim 8, further comprising:

10. The method according to claim 8, wherein the portion of the component adjacent to the opening is inserted into the supply port when the opening engages with the supply port.

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