Injection molding system and injection molding method

Abstract

To provide an injection molding system and an injection molding method.SOLUTION: An injection molding system includes a supply unit for a flowable mixture, an injection unit capable of communicating with the supply unit and including a discharge port for the flowable mixture, a molding apparatus receptive to the flowable mixture and including a mold with a supply port engageable with the discharge port, and a support device disposed between the injection unit and the molding apparatus and configured to facilitate engagement between the injection unit and the molding apparatus. The support device includes a first element connected to the injection unit and a second element disposed on the molding apparatus. The second element includes a first slot configured to receive a protruding portion of the first element, and the protruding portion of the first element is slidable within and along the first slot of the second element.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] (Cross-Reference to Related Applications) This application claims priority from U.S. Provisional Application No. 63 / 379,255 filed on October 12, 2022 and U.S. Patent Application No. 18 / 451,073 filed on August 16, 2023, each of which is incorporated herein by reference in its entirety.

[0002] The present invention relates to an injection molding system and an injection molding method, and in particular, to an injection molding system and an injection molding method for manufacturing a foamed polymer article.

Background Art

[0003] Foamed polymer articles have many advantages such as high strength, light weight, impact resistance, excellent sound insulation and heat insulation. A foamed polymer article can be formed into a molded product having a predetermined shape by injection molding or extrusion. For example, after a polymer material is melted and mixed with a blowing agent in an extrusion system to form a flowable mixture, the mixture is injected or extruded into a molding apparatus to form a desired foamed polymer article. The properties and quality of a foamed polymer article can be improved by adjusting the structure of the injection molding system and adjusting the injection molding system.

Summary of the Invention

[0004] One object of the present invention is to provide an injection molding system and an injection molding method.

[0005] According to one embodiment of the present disclosure, an injection molding system is disclosed. The injection molding system includes a supply unit configured to supply a fluid mixture of a polymer material and a foaming agent; an injection unit communicating with the supply unit, located distal to the supply unit and including a nozzle configured to discharge the fluid mixture; a molding apparatus configured to receive the fluid mixture from the nozzle, including a mold cavity and an opening that is communicable with the mold cavity and engageable with the nozzle; and a support device configured to facilitate engagement between the injection unit and the molding apparatus. The support device includes a first element connected to the injection unit and a second element located in the molding apparatus. The second element includes a slot configured to receive a protruding portion of the first element, the protruding portion of the first element being slidable within and along the slot of the second element.

[0006] According to one embodiment of this disclosure, an injection molding method is disclosed. The injection molding method includes the steps of providing an injection molding system, the injection molding system comprising an injection unit and a molding apparatus, the injection unit comprising a nozzle configured to discharge a fluid mixture, the molding apparatus comprising a mold cavity and an opening that is communicable to the mold cavity and correspondingly engageable with the nozzle, configured to receive the fluid mixture from the nozzle; providing a support device configured to facilitate engagement between the injection unit and the molding apparatus, the support device comprising a first element connected to the injection unit and a second element disposed in the molding apparatus; aligning a protruding portion of the first element with a slot of the second element; displacing the injection unit to slide the protruding portion of the first element along the slot of the second element; engaging the nozzle with the opening when the protruding portion of the first element engages with the slot of the second element; and injecting the fluid mixture into the mold cavity. [Brief explanation of the drawing]

[0007] The aspects of this disclosure will be best understood from the following detailed description when read in conjunction with the accompanying drawings. Note that, in accordance with standard practice in the 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 some embodiments of the present disclosure. [Figure 2] This is a schematic diagram illustrating some of the injection molding systems according to several embodiments of the present disclosure. [Figure 3] This is a schematic top view showing some of the injection molding systems according to some embodiments of the present disclosure. [Figure 4] This is a schematic diagram illustrating some of the injection molding systems according to several embodiments of the present disclosure. [Figure 5] This is a schematic cross-sectional view showing some of the injection molding systems according to some embodiments of the present disclosure. [Figure 6] This flowchart shows injection molding methods according to some embodiments of the present disclosure. [Figure 7] This is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 8] This is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 9] This is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 10] This is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 11]This is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 12] This is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 13] This is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 14] This is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 15] This is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 16] This is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 17] This is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 18] This is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 19] This is a schematic diagram of an injection molding system according to some embodiments of the present disclosure. [Figure 20] This is a schematic diagram illustrating some of the injection molding systems according to several embodiments of the present disclosure. [Figure 21] This is a schematic top view showing some of the injection molding systems according to some embodiments of the present disclosure. [Figure 22] This is a schematic diagram illustrating some of the injection molding systems according to several embodiments of the present disclosure. [Figure 23] This is a schematic cross-sectional view showing some of the injection molding systems according to some embodiments of the present disclosure. [Figure 24]It is a flow chart illustrating an injection molding method according to some embodiments of the present disclosure. [Figure 25] It is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing steps of an injection molding method according to some embodiments of the present disclosure. [Figure 26] It is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing steps of an injection molding method according to some embodiments of the present disclosure. [Figure 27] It is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing steps of an injection molding method according to some embodiments of the present disclosure. [Figure 28] It is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing steps of an injection molding method according to some embodiments of the present disclosure. [Figure 29] It is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing steps of an injection molding method according to some embodiments of the present disclosure. [Figure 30] It is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing steps of an injection molding method according to some embodiments of the present disclosure. [Figure 31] It is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing steps of an injection molding method according to some embodiments of the present disclosure. [Figure 32] It is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing steps of an injection molding method according to some embodiments of the present disclosure. [Figure 33] It is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing steps of an injection molding method according to some embodiments of the present disclosure. [Figure 34] It is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing steps of an injection molding method according to some embodiments of the present disclosure. [Figure 35] It is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing steps of an injection molding method according to some embodiments of the present disclosure. [Figure 36]This is a side view or schematic cross-sectional view of an injection molding system in one or more manufacturing stages of an injection molding method according to some embodiments of the present disclosure. [Figure 37] This flowchart shows injection molding methods according to some embodiments of the present disclosure. [Modes for carrying out the invention]

[0009] The following disclosure provides many different embodiments or examples for carrying out different features of the present invention. Specific examples of components and arrangements are described below for the sake of brevity of this disclosure. These are, of course, merely examples and are not intended to be limiting. For example, in the following description, forming a first feature above or on a second feature 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 the first and second features are not in direct contact. Furthermore, in various examples in this disclosure, reference numbers and / or letters may be repeated. This repetition is for the purpose of simplification and clarity and does not in itself indicate relationships between the various embodiments and / or configurations discussed.

[0010] Furthermore, spatially relative terms such as “downward,” “below,” “bottom,” “up,” and “top” may also be used herein to describe the relationship between one element or feature and another element or feature, as shown in the drawings, for the sake of clarity. 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 a different direction (it may be rotated 90° or in other directions), and the spatially relative descriptors used herein may be interpreted accordingly.

[0011] Although the numerical ranges and parameters describing the broad scope of this disclosure are approximations, the numerical values ​​described in specific examples are reported as accurately as possible. However, any numerical value inherently includes a certain error that inevitably arises from the standard deviation found in each test measurement. Also, as used herein, the term “about” generally means within 10%, 5%, 1%, or 0.5% of a given value or range. Alternatively, the term “about” means within the acceptable standard error of the mean, as considered by those skilled in the art. Except for examples of operation / work, or unless otherwise specified, all numerical ranges, quantities, values, and percentages such as quantities, durations, temperatures, operating conditions, and ratios of quantities of material disclosed herein 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 the very least, each numerical parameter should be interpreted by applying ordinary rounding techniques in light of the number of significant figures reported. In this specification, a scope may be expressed as from one endpoint to another, or between two endpoints. Unless otherwise specified, all scopes disclosed herein include the endpoints.

[0012] In general, the appearance and physical properties of foamed polymer articles are directly affected by the injection molding process. Therefore, the design of an injection molding system must take into account the injection conditions of the fluid mixture from the injection unit into the molding apparatus so that the fluid mixture can be completely and effectively injected into the molding apparatus to form foamed polymer articles of the desired quality.

[0013] Figure 1 shows a schematic perspective view of a first injection molding system 100 according to one embodiment of the present disclosure. In some embodiments, referring to Figure 1, the first injection molding system 100 includes an injection unit 101 and a molding apparatus 102. The injection unit 101 is engageable with the molding apparatus 102. In some embodiments, the first injection molding system 100 further includes a fluid mixture supply unit 103 that can communicate with the injection unit 101. In some embodiments, the fluid mixture supply unit 103 is configured to generate a fluid mixture and supply it to the injection unit 101.

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

[0015] In some embodiments, the fluid mixture supply unit 103 of the first injection molding system 100 includes an extruder (not shown) for converting a polymer material into a molten state and a mixer (not shown) for mixing a foaming agent with the polymer material. The polymer material is fluidizable from the extruder into the mixer.

[0016] In some embodiments, the injection unit 101 includes an injector 101a. In some embodiments, multiple injectors 101a can be included in the injection unit 101. In some embodiments, the injector 101a is configured to receive a fluid mixture from a fluid mixture supply unit 103 and discharge the fluid mixture from a discharge port 101c. In some embodiments, the injector 101a is configured as a discharge channel, and the discharge port 101c is located distal to the injector 101a and is configured to discharge the fluid mixture.

[0017] In some embodiments, the injector 101a is able to communicate with a mixer or a fluid mixture supply unit 103. In some embodiments, the fluid mixture is discharged from the injector 101a into the molding apparatus 102. The injector 101a is able to engage with the molding apparatus 102. The injector 101a is extendable toward the molding apparatus 102 and retractable toward the molding apparatus 102. In some embodiments, the injector 101a is extendable / retractable perpendicular to a first direction as indicated by arrow A. In some embodiments, the injector 101a is extendable / retractable by a hydraulic mechanism 101e. In some embodiments, the hydraulic mechanism 101e is attached to the injector 101a. In some embodiments, the hydraulic mechanism 101e is located between the fluid mixture supply unit 103 and the injector 101a.

[0018] In some embodiments, the support device 105 is configured to facilitate engagement between the injection unit 101 and the molding apparatus 102. In some embodiments, the support device 105 is positioned above the molding apparatus 102. In some embodiments, the support device 105 includes a first element 101b positioned adjacent to the injector 101a. In some embodiments, the first element 101b is connected to the injection unit 101. The first element 101b is extendable toward the molding apparatus 102 and retractable away from the molding apparatus 102. In some embodiments, the first element 101b is extendable / retractable perpendicularly in a second direction as indicated by arrow B. In some embodiments, the first and second directions are parallel.

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

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

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

[0022] Figure 2 shows a schematic perspective view of the second element 102s of the support device 105, and Figure 3 shows a schematic top view of the second element 102s. In some embodiments, referring to Figures 1 to 3, the support device 105 includes a second element 102s that is positioned on the molding device 102 and is engageable with the first element 101b. In some embodiments, the second element 102s is engageable with the molding device 102. In some embodiments, the second element 102s is engageable with the first mold 102c. In some embodiments, the second element 102s is removably mounted to the molding device 102. In some embodiments, the second element 102s includes a slot 102e defined by a projection 102f.

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

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

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

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

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

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

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

[0030] In some embodiments, referring to Figures 4 and 5, when the molding apparatus 102 is in a closed state, the mold cavity 102i is defined by the first mold 120c and the second mold 102d. In some embodiments, the mold cavity 102i is configured to receive a fluid mixture from the injector 101a through an opening 102h in the second element 102s. The mold cavity 102i is accessible only through the supply port 102j when the molding apparatus 102 is in a closed state. When the molding apparatus 102 is in an open state, the mold cavity 102i is accessible through a gap (not shown) between the first mold 102c and the second mold 102d. In some embodiments, the molding apparatus 102 includes a supply port 102j that can communicate with the mold cavity 102i. In some embodiments, the supply port 102j is located in and penetrates the first mold 102c. In some embodiments, the opening 102h is aligned with the supply port 102j when the second element 102s is placed on the molding apparatus 102, so that the fluid mixture can flow from the injector 101a through the opening 102h and the supply port 102j into the mold cavity 102i. In some embodiments, the opening 102h overlaps with the supply port 102j when the second element 102s is placed on the molding apparatus 102 in a top view.

[0031] In some embodiments, the molding apparatus 102 may be placed on a carrier (not shown) and moved with the carrier. In some embodiments, multiple molding apparatuses 102 are placed on the carrier and arranged in lines, rows, columns, arcs, curves, or any other suitable arrangement. In some embodiments, the carrier is rotatable.

[0032] In some embodiments, referring again to Figures 1, 2 and 3, the support device 105 further includes a third element 101g connected to the injection unit 101, and the second element 102s is configured to receive the first element 101b and the third element 101g. In some embodiments, both the first element 101b and the third element 101g are configured to be received by a first portion 102x and a second portion 102y of a projection 102f.

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

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

[0035] This disclosure also discloses a first injection molding method 200. The first injection molding method 200 includes several operations, and the description and examples are not intended to limit the order of operations. Figure 6 is an embodiment of the first injection molding method 200. In some embodiments, the first injection molding method 200 includes several operations (201-212). Figures 7-18 are schematic cross-sectional views of various stages of the first injection molding method according to some embodiments of this disclosure. In some embodiments, the first injection molding method 200 is carried out by the first injection molding system 100 shown in Figures 1-5 and described above.

[0036] Referring to Figure 7, in operation 201, a first injection molding system 100 is provided, which includes an injection unit 101, a molding apparatus 102, and a support device 105. In some embodiments, the first injection molding system 100 includes the injection unit 101, the molding apparatus 102, and the support device 105, as described above. The molding apparatus 102 is in a closed state. The opening 102h of the second element 102s is aligned with the supply port 102j of the molding apparatus 102, so that the mold cavity 102i is accessible through the opening 102h and the supply port 102j. In some embodiments, the molding apparatus 102 may be placed on a carrier (not shown) and moved with the carrier. In some embodiments, several molding apparatuses 102 are placed on the carrier.

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

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

[0039] In some embodiments, the protruding portion 101h of the third element 101g is aligned with the slot 102e of the second element 102s. In some embodiments, the process of aligning the protruding portion 101h of the third element 101g with the slot 102e of the second element 102s is the same as the process of aligning the protruding portion 101d of the first element 101b with the slot 102e of the second element 102s, so for brevity, repetitive explanations are omitted. In some embodiments, the alignment of the protruding portion 101d of the first element 101b with the slot 102e of the second element 102s, and the alignment of the protruding portion 101h of the third element 101g with the slot 102e are performed simultaneously.

[0040] In operation 204, referring to Figures 8 and 9, the second element 102s is displaced toward the injection unit 101, causing the protruding portion 101d of the first element 101b to slide along the slot 102e of the second element 102s. In operation 205, the discharge port 101c slides within the groove 102g.

[0041] In some embodiments, after horizontal alignment, the second element 102s is moved toward the injection unit 101 along arrow E, as shown in Figure 8. Alternatively, after horizontal alignment, the injection unit 101 is moved toward the second element 102s along arrow L, as shown in Figure 8. In some embodiments, the molding apparatus 102 is moved toward the second element 102s and the injection unit 101 after horizontal alignment of the second element 102s and the injection unit 101. In other words, the molding apparatus 102 is movable while the injection unit 101 and the second element 102s are fixed relative to the molding apparatus 102.

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

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

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

[0045] In operation 207, referring to Figure 11, the discharge port 101c extends toward the molding apparatus 102, engaging the discharge port 101c with the opening 102h.

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

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

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

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

[0050] In operation 209, referring to Figure 13, the fluid mixture 104 is injected into the mold cavity 102i of the molding apparatus 102.

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

[0052] In some embodiments, during the injection of the fluid mixture 104, the discharge port 101c engages with the opening 102h and contacts the step 102k, and the protruding portion 101d of the first element 101b abuts against the projection 102f of the second element 102s. During the injection of the fluid mixture 104 into the mold cavity 102i by the injector 101a, an injection force I is generated toward the second element 102s and / or the molding apparatus 102. In some embodiments, the injection force I acts toward the second element 102s and / or the molding apparatus 102, pushing the second element 102s and / or the molding apparatus 102 toward the injection unit 101, thereby generating a reaction force C acting toward the protruding portion 101d by the projection 102f. The protruding portion 101d abuts against the projection 102f during the injection of the fluid mixture 104. Therefore, engagement between the first element 101b and the second element 102s, as well as engagement between the discharge port 101c and the supply port 102j, are ensured. The fluid mixture 104 flowing out from the mold cavity 102i can be minimized or even prevented.

[0053] In operation 210, referring to Figure 14, the first element 101b is displaced toward the second element 102s after the injection of the fluid mixture 104. In some embodiments, the protruding portion 101d of the first element 101b is disengaged from the projection 102f of the second element 102s after the injection of the fluid mixture 104, but the protruding portion 101d of the first element 101b is received by the slot 102e of the second element 102s.

[0054] In some embodiments, after the injection of the fluid mixture 104, the first element 101b is displaced toward the second element 102s along arrow H as shown in Figure 14 until the first element 101b is disengaged from the second element 102s. In some embodiments, the protruding portion 101d is moved away from the projection 102f. In some embodiments, the first element 101b is moved toward the molding apparatus 102 and disengaged from the projection 102f. In some embodiments, the injector 101a remains stationary when the first element 101b is moving downward, as shown in Figure 14. In some embodiments, the separation of the projection 102f from the protruding portion 101d of the first element 101b is detected by a first sensor 102l.

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

[0056] In operation 211, referring to Figure 15, the injector 101a is displaced away from the molding apparatus 102. In some embodiments, the discharge port 101c is retracted away from the molding apparatus 102 after the injection of the fluid mixture 104.

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

[0058] In operation 212, referring to Figures 16 and 17, the second element 102s and the molding apparatus 102 are displaced away from the injection unit 101, or the injection unit 101 is displaced away from the molding apparatus 102.

[0059] In some embodiments, after disengaging the first element 101b and injector 101a from the second element 102s, the second element 102s and molding apparatus 102 are displaced away from the injection unit 101. Alternatively, after disengaging the first element 101b and injector 101a from the second element 102s, the injection unit 101 is displaced away from the molding apparatus 102. In some embodiments, the second element 102s and molding apparatus 102 move horizontally away from the first element 101b and injector 101a along arrow K, as shown in Figure 16. Alternatively, the first element 101b and injector 101a move horizontally away from the second element 102s and molding apparatus 102 along arrow M, as shown in Figure 16. Figure 17 shows the injection unit 101 and the second element 102s separated from each other after the second element 102s has been displaced away from the injection unit 101.

[0060] In operation 212, referring to Figure 18, the molding apparatus 102 is displaced away from the second element 102s, or the second element 102s is displaced away from the molding apparatus 102.

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

[0062] Figure 19 shows a schematic perspective view of a second injection molding system 300 according to one embodiment of the present disclosure. In some embodiments, referring to Figure 19, the second injection molding system 300 includes an injection unit 101, a molding apparatus 102, and a support device 105 positioned between the injection unit 101 and the molding apparatus 102. In some embodiments, the second injection molding system 300 further includes a fluid mixture supply unit 103 that can communicate with the injection unit 101. In some embodiments, the fluid mixture supply unit 103 is configured to generate a fluid mixture and supply it to the injection unit 101. In some embodiments, the fluid mixture includes polymer materials such as ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethane (TPU), and thermoplastic polyester elastomer (TPEE). In some embodiments, the fluid mixture includes recyclable materials. In some embodiments, the fluid mixture further includes a blowing agent.

[0063] In some embodiments, the fluid mixture supply unit 103 of the second injection molding system 300 includes an extruder (not shown) for converting the polymer material into a molten state and a mixer (not shown) for mixing a foaming agent with the polymer material. The polymer material is fluidizable from the extruder into the mixer.

[0064] In some embodiments, the injection unit 101 includes several injectors 101a positioned between a first element 101b and a third element 101g of a support device 105. In some embodiments, the support device 105 surrounds the injectors 101a. In some embodiments, each injector 101a is configured to receive a fluid mixture from a fluid mixture supply unit 103 and discharge the fluid mixture from its outlet 101c. In some embodiments, each injector 101a is communicable with a mixer or the fluid mixture supply unit 103. In some embodiments, the fluid mixture is discharged from the injectors 101a into a molding device 102. Each injector 101a is engageable with a second element 102s of the support device 105. In some embodiments, all injectors 101a are engaged with the second element 102s. In some embodiments, each injector 101a is extendable / retractable perpendicular to the first direction, as indicated by arrow A. In some embodiments, the injectors 101a are extendable / retractable independently of each other. In some embodiments, each of the injectors 101a is extendable / retractable by a hydraulic mechanism 101e. In some embodiments, the movement of each injector 101a is actuated and controlled by a single hydraulic mechanism 101e.

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

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

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

[0068] In some embodiments, the molding apparatus 102 includes a first mold 102c and a second mold 102d that is engaged with the first mold 102c. In some embodiments, the first mold 102c is an upper mold, and the second mold 102d is a lower mold. In some embodiments, the second element 102s is engaged with the first mold 102c. In some embodiments, the molding apparatus 102 may be arranged on a carrier (not shown) and moved with the carrier. In some embodiments, multiple molding apparatuses 102 are arranged on a carrier, and the molding apparatuses are arranged in lines, rows, columns, arcs, curves, or any other suitable arrangement. In some embodiments, the carrier is rotatable.

[0069] Figure 20 shows a schematic perspective view of the second element 102s, and Figure 21 shows a schematic top view of the second element 102s. In some embodiments, referring to Figures 19 to 21, the support device 105 includes a second element 102s that can engage with the first element 101b and the third element 101g. In some embodiments, the second element 102s is positioned on the molding device 102. In some embodiments, the second element 102s includes a slot 102e defined by a projection 102f and a slot 102o defined by a projection 102p.

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

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

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

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

[0074] In some embodiments, the step 102k is formed within the groove 102g adjacent to the opening 102h. In some embodiments, a second sensor 102m is positioned within the groove 102g and is configured to sense contact between the discharge port 101c and the groove 102g.

[0075] In some embodiments, the second sensor 102m is located within the opening 102h. The second sensor 102m is not particularly limited as long as it is capable of sensing pressure and providing pressure information. In some embodiments, multiple second sensors 102m are located within the opening 102h and are configured to sense the position and contact between the discharge port 101c and the molding apparatus 102. The number and arrangement of the multiple second sensors 102m are not particularly limited and can be located anywhere within the opening 102h, for example. However, the present invention is not limited thereto.

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

[0077] This disclosure also discloses a second injection molding method 400. The second injection molding method 400 includes several operations, and the description and examples are not intended to limit the order of operations. Figure 24 is an embodiment of the second injection molding method 400. In some embodiments, the second injection molding method 400 includes several operations (401-413). Figures 25-36 are schematic cross-sectional views of various stages of the second injection molding method according to some embodiments of this disclosure. In some embodiments, the second injection molding method 400 is carried out by a second injection molding system 300, as shown in Figures 19-23 and discussed above.

[0078] In operation 401, referring to Figure 25, a second injection molding system 300 is provided, which includes an injection unit 101, a molding apparatus 102, and a support device 105. In some embodiments, the second injection molding system 300 includes the injection unit 101, the molding apparatus 102, and the support device 105, as described above. The molding apparatus 102 is in a closed state. The opening 102h of the second element 102s is aligned with several supply ports 102j of the molding apparatus 102, so that the mold cavity 102i is accessible through the opening 102h and the supply ports 102j.

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

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

[0081] In operation 405, referring to Figures 26 and 27, the injection unit 101 is displaced such that the protruding portion 101d of the first element 101b slides along the first slot 102e of the second element 102s, and the protruding portion 101h of the third element 101g slides along the second slot 102e of the second element 102s. In operation 406, the discharge port 101c slides within the groove 102g.

[0082] In some embodiments, after horizontal alignment, the second element 102s is moved toward the injection unit 101 along arrow E, as shown in Figure 26. Alternatively, after horizontal alignment, the injection unit 101 is moved toward the second element 102s along arrow L, as shown in Figure 26. Figure 27 is a schematic cross-sectional view of the second injection molding system 300 of Figure 26. In some embodiments, the first element 101b slides along the first slot 102e, the third element 101g slides along the second slot 102e, and the discharge port 101c or end portion of the injector 101a slides along the groove 102g. In some embodiments, the second element 102s is moved until the first element 101b is positioned in the first slot 102e, the third element 101g is positioned in the second slot 102e, and the discharge port 101c or end portion of the injector 101a is aligned perpendicularly with the opening 102h. As shown in Figure 27, projection 102f is positioned opposite the protruding portion 101d of the first element 101b, and projection 102p is positioned opposite the protruding portion 101h of the third element 101g. The first element 101b, the third element 101g, and the injector 101a are not in contact with the second element 102s. In some embodiments, the discharge port 101c of the injector 101a is aligned with the opening 102h. In some embodiments, the distance D3 between the bottom surface of the protruding portion 101h and the second element 102s is substantially greater than the distance D4 between the end of the discharge port 101c and the top surface of the molding apparatus 102.

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

[0084] In operation 408, referring to Figure 29, the discharge port 101c extends toward the molding device 102, engaging the discharge port 101c with the molding device 102.

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

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

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

[0088] In some embodiments, contact between the second element 102s and the first element 101b is detected by the first sensor 102l. In some embodiments, contact between the projection 102f and the protruding portion 101d of the first element 101b is detected by the first sensor 102l. In some embodiments, contact between the second element 102s and the first element 101b is detected continuously. In some embodiments, contact between the second element 102s and the third element 101g is detected by the third sensor 102q, which is located on the projection 102p and within the second slot 102e. In some embodiments, contact between the second element 102s and the third element 101g is detected by the third sensor 102q. In some embodiments, contact between the projection 102p and the protruding portion 101h of the third element 101g is detected by the third sensor 102q. In some embodiments, contact between the second element 102s and the third element 101g is detected continuously.

[0089] In operation 410, referring to Figure 31, the fluid mixture 104 is injected into the mold cavity 102i of the molding apparatus 102.

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

[0091] In some embodiments, during the injection of the fluid mixture 104, the outlet 101c engages with the molding apparatus 102, the protruding portion 101d of the first element 101b abuts against the projection 102f of the second element 102s, and the protruding portion 101h of the third element 101g abuts against the projection 102p of the fourth element 102o. During the injection of the fluid mixture 104 into the mold cavity 102i by the injector 101a, an injection force I is generated toward the molding apparatus 102. In some embodiments, the injection force I acts on the molding apparatus 102, pushing it away from the injection unit 101, thereby generating a reaction force C acting on the protruding portion 101d by the projection 102f. During the injection of the fluid mixture 104, the protruding portion 101d abuts against the projection 102f, and the protruding portion 101h abuts against the projection 102p. Therefore, engagement between the first element 101b and the second element 102s, engagement between the third element 101g and the second element 102s, and engagement between the discharge port 101c and the supply port 102j are ensured. The fluid mixture 104 flowing out from the mold cavity 102i can be minimized or even prevented.

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

[0093] In some embodiments, after the injection of the fluid mixture 104, the first element 101b and the third element 101g are displaced toward the second element 102s along arrow H, as shown in Figure 32, until the first element 101b is disengaged from the second element 102s. In some embodiments, the protruding portion 101d moves away from the projection 102f, and the protruding portion 101h moves away from the projection 102p. In some embodiments, the first element 101b is moved toward the molding apparatus 102 to disengage from the projection 102f, and the third element 101g is moved toward the molding apparatus 102 to disengage from the projection 102p. In some embodiments, the injector 101a remains stationary while the first element 101b and the third element 101g are moving downward, as shown in Figure 32. In some embodiments, the separation of the projection 102f of the first element 101b from the protruding portion 101d is detected by the first sensor 102l, and the separation of the projection 102p of the third element 101g from the protruding portion 101h is detected by the third sensor 102q.

[0094] In operation 412, referring to Figure 33, the injector 101a is displaced away from the molding apparatus 102. In some embodiments, the discharge port 101c is retracted away from the molding apparatus 102 after the injection of the fluid mixture 104.

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

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

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

[0098] In some embodiments, after disengaging the molding apparatus 102 from the second element 102s, the molding apparatus 102 is displaced away from the second element 102s. In some embodiments, the molding apparatus 102 moves horizontally away from the second element 102s along arrow K, as shown in Figure 35. In some embodiments, the molding apparatus 102 is displaced away from the second element 102s by rotating a carrier (not shown) located beneath the molding apparatus 102, and another molding apparatus (not shown) may be located beneath the second element 102s. Alternatively, after disengaging the second element 102s from the molding apparatus 102, the injection unit 101, the molding apparatus 102, and the second element 102s are separated from each other. In some embodiments, the molding apparatus 102 moves horizontally away from the second element 102s. Alternatively, the second element 102s moves horizontally away from the molding apparatus 102. Figure 36 shows that the second element 102s and the molding apparatus 102 are separated from each other after the molding apparatus 102 has moved away from the second element 102s.

[0099] This disclosure also discloses a third injection molding method 500. The third injection molding method 500 includes several operations, and the description and examples are not intended to limit the order of the operations. Figure 37 is an embodiment of the third injection molding method 500. In some embodiments, the third injection molding method 500 includes several operations (501-506). In some embodiments, the third injection molding method 500 is carried out by the first injection molding system 100 shown in Figures 1-5 above or the second injection molding system 300 shown in Figures 19-23.

[0100] In operation 501, an injection molding system is provided, the injection molding system comprising an injection unit and a molding apparatus, the injection unit comprising a discharge port configured to discharge a fluid mixture, and the molding apparatus comprising a mold cavity and a supply port configured to receive a fluid mixture from the discharge port, the supply port communicating with the mold cavity and correspondingly engaging with the discharge port.

[0101] In operation 502, a support device is provided which is configured to facilitate engagement between the injection unit and the molding apparatus, the support device comprising a first element connected to the injection unit and a second element positioned in the molding apparatus.

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

[0103] In operation 504, the injection unit is displaced so that the protruding portion of the first element slides along the slot of the second element.

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

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

[0106] One aspect of the present disclosure relates to an injection molding system. The injection molding system includes a supply unit configured to supply a fluid mixture of a polymer material and a foaming agent; an injection unit communicating with the supply unit, located distal to the supply unit and including a discharge port configured to discharge the fluid mixture; a molding apparatus configured to receive the fluid mixture from the discharge port, including a mold cavity and a supply port communicating with the mold cavity and engaging with the discharge port; and a support device located between the injection unit and the molding apparatus and configured to facilitate engagement between the injection unit and the molding apparatus. The support device includes a first element connected to the injection unit and a second element located in the molding apparatus. The second element includes a slot configured to receive a protruding portion of the first element, the protruding portion of the first element being slidable within and along the first slot of the second element.

[0107] In some embodiments, the second element includes an opening configured to receive the discharge port of an injection unit. In some embodiments, the second element further includes a projection for defining a first slot, and the first slot and projection are laterally elongated. In some embodiments, the protruding portion of the first element is engageable with the projection and slidable within the slot. In some embodiments, the second element further includes a groove configured to receive the discharge port, and the groove is laterally elongated along the second element and parallel to the first slot. In some embodiments, the discharge port is slidable within and along the groove. In some embodiments, the second element further includes an opening located within the groove. In some embodiments, a first sensor is located within the first slot and configured to sense contact between the protruding portion and the first slot. In some embodiments, a second sensor is located within the groove and configured to sense contact between the discharge port and the groove. In some embodiments, the height of the first slot is greater than the thickness of the protruding portion of the first element. In some embodiments, the support device further includes a third element connected to an injection unit, and the first slot is configured to receive the first and third elements. In some embodiments, the support device further includes a third element connected to the injection unit, the second element further including a second slot configured to receive the third element.

[0108] Aspects of the present disclosure relate to an injection molding method. The injection molding method comprises the steps of providing an injection molding system, the injection molding system comprising an injection unit and a molding apparatus, the injection unit comprising a discharge port configured to discharge a fluid mixture, the molding apparatus comprising a mold cavity and a supply port communicating with the mold cavity and correspondingly engaging with the discharge port, configured to receive the fluid mixture from the discharge port, and the support apparatus comprising a support device configured to facilitate engagement between the injection unit and the molding apparatus, the support device comprising the injection unit The process includes: a first element connected to a torch and a second element positioned in the molding apparatus; a step of aligning a protruding portion of the first element with a slot in the second element; a step of displacing the injection unit to slide the protruding portion of the first element along the slot in the second element; a step of displacing the discharge port within the opening of the second element to engage the discharge port with the supply port once the protruding portion of the first element engages with the slot in the second element; and a step of injecting the fluid mixture into the mold cavity.

[0109] In some embodiments, the method further includes the steps of aligning a discharge port with a groove configured to receive a discharge port, wherein the groove is laterally elongated along a second element and parallel to a slot, and sliding the discharge port into the groove. In some embodiments, the alignment of the protruding portion of the first element with the slot of the second element and the alignment of the discharge port with the groove are performed simultaneously. In some embodiments, the method further includes the steps of extending the discharge port toward the molding apparatus and engaging the discharge port with a supply port, and retracting the discharge port from the molding apparatus after the injection of the fluid mixture. In some embodiments, the method further includes the steps of moving the protruding portion of the first element so as to abut a projection of the second element while the protruding portion of the first element is received by the slot of the second element, and disengaging the protruding portion of the first element from the slot of the second element after the injection of the fluid mixture, wherein the slot is defined by the projection. In some embodiments, the first element is moved away from the molding apparatus so as to abut a projection, and moved toward the molding apparatus so as to disengage from the projection. In some embodiments, the method further includes the step of moving the protruding portion of the first element toward a molding apparatus after injection of a fluid mixture, while the protruding portion of the first element is received by the slot of the second element, wherein the injection unit remains stationary while the support device is moving toward the molding apparatus. In some embodiments, during injection of the fluid mixture, the protruding portion of the first element abuts against the projection of the second element, and the discharge port is in communication with a supply port.

[0110] The foregoing description outlines the features of several embodiments so that those skilled in the art may better understand the 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 do not deviate from the spirit and scope of the disclosure, and that various modifications, substitutions, and alterations of the disclosure can be made without departing from the spirit and scope of the disclosure.

[0111] Furthermore, the scope of this application is not limited to specific embodiments of the processes, machines, manufactures, material 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, material 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 utilized in accordance with the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufactures, material compositions, means, methods, and steps.

Claims

1. An injection molding system, A supply unit configured to supply a fluid mixture of polymer material and foaming agent, An injection unit capable of communicating with the supply unit, the injection unit being located distal to the supply unit and including a discharge port configured to discharge the fluid mixture, A molding apparatus configured to receive the fluid mixture from the discharge port, A support device comprising a first element and a second element configured to engage with or disengage from the first element, Equipped with, An injection molding system wherein one of the first element and the second element is connected to the injection unit, away from the supply unit and adjacent to the discharge port, the second element includes a first slot configured to receive a protruding portion of the first element, the protruding portion of the first element is slidable along it within the first slot of the second element, and the discharge port and the first element are each extendable toward the molding apparatus and retractable toward the molding apparatus.

2. The molding apparatus is Mold cavity and, A supply port that can communicate with the mold cavity and engage with the discharge port, Includes, The injection molding system according to claim 1, wherein the support device is positioned between the injection unit and the molding apparatus and is configured to facilitate engagement between the injection unit and the molding apparatus, the first element being connected to the injection unit and the second element being positioned on the molding apparatus.

3. The injection molding system according to claim 1, wherein the support device includes an opening configured to receive the discharge port of the injection unit.

4. The injection molding system according to claim 1, wherein the support device is configured to receive the discharge port and further includes a groove extending along the first slot.

5. The injection molding system according to claim 4, wherein the discharge port is slidable within the groove along the groove.

6. The injection molding system according to claim 4, wherein the second element further includes an opening disposed within the groove.

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

8. An injection molding method, A step of providing an injection molding system, wherein the injection molding system includes an injection unit and a molding apparatus, the injection unit includes a discharge port configured to discharge a fluid mixture, and the molding apparatus includes a mold cavity and a supply port that is in communication with the mold cavity and correspondingly engageable with the discharge port, configured to receive the fluid mixture from the discharge port. A step of providing a support device configured to facilitate engagement between the injection unit and the molding apparatus, wherein the support device includes a first element, a second element configured to engage with or disengage from the first element, and an opening configured to receive the discharge port, the discharge port engaging with the supply port, one of the first element and the second element being connected to the injection unit and the other being connected to the molding apparatus, The steps include aligning the protruding portion of the first element with the slot of the second element, The steps include: displacing the injection unit or the molding apparatus to slide the protruding portion of the first element along the slot of the second element; When the protruding portion of the first element engages with the slot of the second element, the step of displacing the discharge port within the opening and engaging the discharge port with the supply port, The steps include injecting the fluid mixture into the mold cavity, Includes, A method wherein the discharge port and the first element are extendable toward the molding apparatus and retractable from the molding apparatus, respectively.

9. The support device further includes a groove, and the step of aligning the discharge port with a groove configured to receive the discharge port, wherein the groove is elongated laterally parallel to the slot, and the step The steps include sliding the discharge port within the groove, The method according to claim 8, further comprising:

10. The steps include moving the protruding portion of the first element so that it contacts the projection of the second element while the protruding portion of the first element is received by the slot of the second element, After the injection of the fluid mixture, the step of disengaging the protruding portion of the first element from the slot of the second element, It further includes, The method according to claim 8, wherein the slot is defined by the projection.

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