Molding device and molding method

Abstract

Provision of a molding device and a molding method. The molding apparatus and molding method of the present invention comprises, wherein the molding apparatus includes an upper die, a lower die, and an intermediate die, wherein the lower die is positioned below the upper die, the intermediate die is positioned between the upper die and the lower die, and the intermediate die is movably installed on the lower die through a position control mechanism.

Description

Technology Field

[0001] The present invention relates to a molding apparatus and a molding method, and more particularly to a molding apparatus and a molding method suitable for use in injection molding or extrusion molding.

[0002] (Cross-reference of related applications)

[0003] This application claims priority to U.S. Patent Application No. 17 / 731,764 filed on April 28, 2022, which is incorporated herein by reference as if in whole. Background Technology

[0004] Foamed polymer molded articles have many advantages, such as high strength, light weight, impact resistance, and good sound insulation and thermal insulation. Foamed polymer molded articles can be formed into molded articles having a predetermined shape by injection molding or extrusion molding. For example, a polymer material can be melted through an injection molding machine and mixed with a foaming agent to form a mixture, and then the molten polymer material is injected or extruded into a mold cavity under pressure to form a desired foamed polymer molded article. The characteristics or applications of the foamed polymer molded article can be changed by changing the composition of the mixture or adjusting the molding method.

[0005] Generally, since the appearance and physical properties of foamed polymer molded articles are directly influenced by the molding process, the mold design must consider the fluidity of the mixture to ensure uniform and rapid distribution within the cavity. Furthermore, it is necessary to maintain the original physical properties by ensuring a high and uniform distribution density of air bubbles within the mixture during the molding process. While foamed polymer molded articles produced using molds offer many advantages and applications, the limitations and restrictions stemming from their drawbacks have not yet been overcome. The problem to be solved

[0006] One objective of the present invention is to provide a molding apparatus and a molding method. means of solving the problem

[0007] According to one embodiment of the present invention, a molding apparatus is disclosed. The molding apparatus comprises an upper die, a lower die, and an intermediate die. The lower die is positioned below the upper die. The intermediate die is positioned between the upper die and the lower die. The intermediate die is movably installed on the lower die through a position control mechanism.

[0008] According to one embodiment of the present invention, a molding method is disclosed. The molding method comprises: (a) a process of providing a lower die and an intermediate die movably installed in the lower die; (b) a process of defining a receiving space by engaging the upper die with the lower die and placing the intermediate die within the receiving space, wherein the upper die, the intermediate die, and the lower die jointly define a mold cavity; (c) a process of injecting a material into the mold cavity and at least partially surrounding the intermediate die; and (d) a process of forming a molded article with the material.

[0009] Aspects of the present invention will be better understood from the accompanying drawings and the following detailed description. It should be noted that, in accordance with standard industry practice, various features are not at an accurate scale. In practice, the dimensions of various features may be arbitrarily increased or decreased to clarify the description. Brief explanation of the drawing

[0010] FIG. 1a is a schematic perspective view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 1b is a side view of the molding device of FIG. 1a. FIG. 2a is a schematic perspective view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 2b is a side view of the molding device of FIG. 2a. FIG. 3a is a schematic perspective view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 3b is a side view of the molding device of FIG. 3a. FIG. 4a is a schematic perspective view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 4b is a side view of the molding device of FIG. 4a. FIG. 5a is a schematic perspective view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 5b is a side view of the molding device of FIG. 5a. FIG. 6a is a schematic perspective view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. Fig. 6b is a side view of the molding device of Fig. 6a. FIG. 7 is a schematic side view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 8 is a schematic perspective view of the molded article based on some embodiments of the present invention. FIG. 9 is a schematic side view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 10 is a schematic side view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 11 is a schematic side view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 12 is a schematic side view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 13 is a schematic side view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 14 is a schematic side view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 15 is a schematic side view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 16a is a schematic perspective view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 16b is a side view of the molding device of FIG. 16a. FIG. 17a is a schematic perspective view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 17b is a side view of the molding device of FIG. 17a. FIG. 18a is a schematic perspective view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 18b is a side view of the molding device of FIG. 18a. FIG. 19a is a schematic perspective view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 19b is a side view of the molding device of FIG. 19a. FIG. 20 is a schematic side view of a molding apparatus in one or more manufacturing steps of a molding method based on some embodiments of the present invention. FIG. 21 is a flowchart illustrating a molding method based on some embodiments of the present invention. Specific details for implementing the invention

[0011] In the following, other embodiments or examples are disclosed to illustrate other features of the present invention. To simplify the description of the present invention, specific examples of components and arrangements are shown below. Of course, they are illustrative and are not intended to be limiting. For example, in the following description, the formation of the first element on the second element may include an embodiment in which the first element and the second element are in direct contact, or an embodiment in which other elements are included between the first element and the second element and the first element and the second element are not necessarily in direct contact. Additionally, in other embodiments of the present invention, reference numerals (numbers and / or letters) may be repeated. This repetition is intended for simplicity and clarity and does not, in itself, determine the relationship between the other embodiments and / or configurations being discussed.

[0012] Additionally, spatial relative terms such as “beneath,” “below,” “lower,” “above,” and “upper” may be used in this specification to facilitate description of the relationship between one element or feature and another element or feature as illustrated in the drawings. Spatial relative terms are intended to include various directions of the device in use or operation in addition to the directions depicted in the drawings. The device may be oriented in other directions (rotated 90 degrees or oriented in other directions), and spatial relative terms used in this specification should be interpreted accordingly.

[0013] The numerical ranges and parameters expressed broadly in the present invention are approximations, but the figures described in the specific examples are reported as accurately as possible. However, any figure inherently contains a specific error resulting from the standard deviation inevitably observed in each of their test measurements. As used herein, the term “approximately” refers to within 10%, 5%, 1%, or 0.5% of the value or range provided. Or the term “approximately” refers to within the standard error of the sample mean acceptable when examined by a person skilled in the art. Except for operational examples / executions, or unless otherwise expressly stated, all numerical ranges, quantities, values, ratios, etc., regarding the quantity of material, length of time, temperature, operating conditions, ratio of amount, etc. disclosed herein are to be understood as being modified by the term “approximately” in all cases. Accordingly, unless specifically indicated otherwise, the numerical parameters described in the present invention and the appended claims may vary depending on the purpose. Finally, each numerical parameter must be interpreted by considering the number of reported valid figures and applying ordinary estimation methods. In this specification, ranges are expressed as from one endpoint to another endpoint, or between two endpoints. All ranges disclosed in this specification include endpoints unless otherwise stated.

[0014] FIGS. 1a to 8 illustrate a molding method for manufacturing a molded article based on some embodiments of the present invention. In some embodiments, the method is for manufacturing the molded article (6) shown in FIG. 8.

[0015] As illustrated in FIGS. 1a and 1b, a molding device (1) is provided. FIGS. 1a is a schematic perspective view of the molding device (1) in a first manufacturing step based on an embodiment of some of the present invention. FIGS. 1b is a side view of the molding device (1) of FIGS. 1a. The molding device (1) may include an upper mold (2), a lower mold (3), an intermediate mold (4), and a position control mechanism (5).

[0016] In some embodiments, the upper mold (2) corresponds to the lower mold (3) in some configurations, such as dimensions and shape. The upper mold (2) is placed on the lower mold (3) and can be engaged with the lower mold (3). In some embodiments, the provision of the molding device (1) may include conveying the lower mold (3) toward the upper mold (2). By doing so, the lower mold (3) is placed below the upper mold (2) for a subsequent process. In some embodiments, the upper mold (2) may be positionally aligned with the lower mold (3). In the embodiments shown in FIGS. 1a and 1b, the molding device (1) is in an open configuration.

[0017] The upper mold (2) may have an upper surface (21) and a lower surface (22) opposite to the upper surface (21). The upper mold (2) may define a concave portion (23) and a passage (24). The lower surface (22) of the upper mold (2) may face the lower mold (3) and the intermediate mold (4). The concave portion (23) of the upper mold (2) may be concavely sunken from the lower surface (22) of the upper mold (2). The configuration (e.g., dimensions or shape) of the concave portion (23) of the upper mold (2) may correspond to the configuration (e.g., dimensions or shape) of the intermediate mold (4). The concave portion (23) of the upper mold (2) may include a first inner surface (231) and a second inner surface (232). The second inner surface (232) may be extended between the first inner surface (231) and the lower surface (22) of the upper mold (2). The first inner surface (231) and the second inner surface (232) may be in a shape that substantially follows the intermediate mold (4).

[0018] In some embodiments, the passage (24) may be extended through the upper mold (2) or may have an opening (241) on the upper surface (21) of the upper mold (2). In some embodiments, when the molding device (1) is configured as a closed structure as shown in FIG. 3a and FIG. 3b, the passage (24) may be in communication with the concave portion (23) of the upper mold (2) or the mold cavity (14). Alternatively, the passage (24) may be in communication with the concave portion (23) of the upper mold (2). Thus, the concave portion (23) of the upper mold (2) may be accessible through the passage (24). For simplicity and clarity, only one passage (24) is shown, but it should be understood that any appropriate number of passages (24) can be formed in the mold (2). In some embodiments, the number of passages (24) is equal to the number of concave portions (23) of the mold (2). In some embodiments, the number of concave portions (23) of the mold (2) is greater than the number of passages (24). In some embodiments, the number of passages (24) is greater than the number of concave portions (23) of the mold (2).

[0019] In some embodiments, instead of configuring the passage (24) in the upper mold (2), the passage (24) may be configured in the lower mold (3) to access the recess (33) of the lower mold (3) or the mold cavity (14) when the molding device (1) is configured in a closed configuration as shown in FIGS. 3a and 3b. In some embodiments, the passage (24) may be configured on the side wall of the lower mold (3), the bottom of the lower mold (3), or any suitable location so that the passage (24) can communicate with the mold cavity (14) when the molding device (1) is configured in a closed configuration as shown in FIGS. 3a and 3b.

[0020] The lower mold (3) may be positioned below the upper mold (2). The lower mold (3) may have an upper surface (31) and a lower surface (32) opposite to the upper surface (31). The lower mold (3) may define a concave portion (33) and a hole structure (34). The upper surface (31) of the lower mold (3) may face the upper mold (2) and the intermediate mold (4). The concave portion (33) of the lower mold (3) may be recessed from the upper surface (31) of the lower mold (3). The configuration (e.g., dimensions or shape) of the concave portion (33) of the lower mold (3) may correspond to the configuration (e.g., dimensions or shape) of the lower surface of the intermediate mold (4). The location of the concave portion (33) of the lower mold (3) may be directly below the intermediate mold (4). The concave portion (33) of the lower mold (3) may be part of the mold cavity (14) when the molding device (1) is configured as a closed structure as shown in FIG. 3a and FIG. 3b.

[0021] In some embodiments, the hole structure (34) may be positioned outside the recess (33) of the lower mold (3). Accordingly, the hole structure (34) does not need to be in communication with the recess (33) of the lower mold (3). Accordingly, the recess (33) of the lower mold (3) does not need to be accessible through the hole structure (34). In some embodiments, the hole structure (34) may be extended through the lower mold (3) or may not be extended. The hole structure (34) may include a first hole (341) and a second hole (342) that are in communication with each other. The first hole (341) may have an opening on the upper surface (31) of the lower mold (3). The second hole (342) is located below the first hole (341). The size (e.g., width or diameter) of the second hole (342) is smaller than the size (e.g., width or diameter) of the first hole (341) and forms a stepped structure (343).

[0022] For simplicity and clarity, only one hole structure (34) is shown, but it should be understood that any appropriate number of hole structures (34) can be configured in the lower mold (3). In some embodiments, the hole structure (34) may be used to introduce part of the position control mechanism (5). Accordingly, the number of hole structures (34) may be equal to the number of position control mechanisms (5). In some embodiments, the number of hole structures (34) may be 2 or 3, and the downward pressure applied from the upper mold (2) to the position control mechanism (5) and the intermediate mold (4) can be supported in a balanced or substantially uniform manner.

[0023] The intermediate mold (4) is positioned between the upper mold (2) and the lower mold (3), and may be movably installed in the lower mold (3) through the position control mechanism (5). The intermediate mold (4) may be movable between the upper mold (2) and the lower mold (3). In some embodiments, the intermediate mold (4) may be movable between the upper mold (2) and the lower mold (3) by operating the position control mechanism (5). In some embodiments, the position control mechanism (5) may drive or operate the intermediate mold (4) to move it along the direction between the upper mold (2) and the lower mold (3) or along the height of the molding device (1). It may be understood that the maximum displacement amount of the intermediate mold (4) is limited by the position control mechanism (5). That is, the gap or distance between the intermediate type (4) and the lower type (3) is controlled by the position control mechanism (5). Also, the gap or distance between the intermediate type (4) and the upper type (2) is not controlled by the position control mechanism (5).

[0024] As illustrated in FIG. 1a and FIG. 1b, the intermediate type (4) may include a main body part (41) and a shoe type (42). The main body part (41) may be connected to the rear end of the shoe type (42). In some embodiments, the main body part (41) and the shoe type (42) may be formed integrally as an integral structure. The main body part (41) may have an upper surface (411) and a lower surface (412) opposite to the upper surface (411). The shoe type (42) may have an upper surface (421), a lower surface (422) opposite to the upper surface (421), and an outer surface (423) extending between the upper surface (421) and the lower surface (422). Additionally, the said spherical shape (42) may define at least one concave portion (43) that is concavely sunken from the said outer surface (423). The said concave portion (43) of the said intermediate shape (4) may be part of the said mold cavity (14) when the said molding device (1) is in a closed configuration as shown in FIG. 3a and FIG. 3b. In some embodiments, at least one said concave portion (43) may include a plurality of concave portions (43) that are connected to each other and extend to the said lower surface (422) of the said spherical shape (42). In some embodiments, the said spherical shape (42) may also define at least one lower surface concave portion (not shown) that is concavely sunken from the said lower surface (422) of the said spherical shape (42).

[0025] The upper surface (421) of the shoe shape (42) may be substantially the same as the upper surface (411) of the main body part (41), or it may be a common plane. Accordingly, the upper surface of the intermediate shape (4) may include the upper surface (421) of the shoe shape (42) and the upper surface (411) of the main body part (41). Additionally, the lower surface (422) of the shoe shape (42) may be substantially the same as the lower surface (412) of the main body part (41), or it may be a common plane. Accordingly, the lower surface of the intermediate shape (4) may include the lower surface (422) of the shoe shape (42) and the lower surface (412) of the main body part (41). As a result, the maximum thickness of the shoe type (42) may be substantially equal to the maximum thickness of the main body part (41) and the maximum thickness of the intermediate type (4).

[0026] The position control mechanism (5) may be connected to or installed on the lower surface (412) of the main body part (41) of the intermediate type (4). The position control mechanism (5) drives or operates the intermediate type (4) upward so that when the molding device (1) is in an open configuration, a gap (G) can be created between the upper surface (31) of the lower type (3) and the lower surface of the intermediate type (4) (including the lower surface (422) of the shoe type (42) and the lower surface (412) of the main body part (41)). That is, the position control mechanism (5) can create relative movement between the intermediate type (4) and the lower type (3). As shown in FIGS. 1a and 1b, when the molding device (1) is in an open configuration, the gap (G) reaches a maximum value.

[0027] In some embodiments, a portion of the position control mechanism (5) may be introduced into the hole structure (34) of the lower mold (3). Accordingly, when the molding device (1) is in a closed configuration, the entire position control mechanism (5) may be introduced into the hole structure (34) of the lower mold (3), and the lower surface (412) of the main body part (41) may come into contact with the upper surface (31) of the lower mold (3).

[0028] As illustrated in FIG. 1a and FIG. 1b, the position control mechanism (5) may include at least one ejector (51) and an elastic mechanism (52). The ejector (51) may be a pin, a support, a post, or a columnar body, and may be used to guide the direction of movement of the intermediate type (4). The upper end (first end) of the ejector (51) may be connected to or installed on the lower surface (412) of the main body part (41) of the intermediate type (4), and the lower end (second end) of the ejector (51) may be extended through the first hole (341) of the hole structure (34) and into the second hole (342) of the hole structure (34). The elastic mechanism (52) may be used to control the movement of the ejector (51) or to drive the ejector (51). For example, the elastic mechanism (52) may be a spring or an elastic body surrounding the ejector (51). The upper end of the elastic mechanism (52) may be connected to or installed on the lower surface (412) of the main body part (41) of the intermediate type (4), and the lower end of the elastic mechanism (52) may be connected to or installed on the stepped structure (343) of the hole structure (34) of the lower type (3). When a downward force is applied to the intermediate type (4) to move the intermediate type (4) downward and drive it to press the elastic mechanism (52), elastic potential energy is accumulated in the pressed elastic mechanism (52). When the downward force is released, the intermediate type (4) is pressed upward by the elastic potential energy. It is understood that the position control mechanism (5) may be a piston having a compression phase and an elastic recovery phase, or other suitable mechanism. In some embodiments, the elastic mechanism (52) may be omitted, and the lower end of the ejector (51) may be connected to a suitable actuator. By doing so, the movement of the ejector (51) may not be controlled by elastic potential energy.

[0029] In some embodiments, the intermediate mold (4) may be detachable from the lower mold (3) and the position control mechanism (5). It is understood that the size or appearance of the molded product (6) (Fig. 8) may correspond to the size or appearance of the intermediate mold (4). Accordingly, in order to manufacture a different molded product (6) (Fig. 8) having a different size or a different appearance, a different intermediate mold (4) having a different size or a different appearance may be adopted and modified. When the intermediate mold (4) is modified, the concave portion (33) of the lower mold (3) and the concave portion (23) of the upper mold (2) may be modified accordingly.

[0030] As illustrated in FIGS. 2a and 2b, the distance between the upper mold (2) and the lower mold (3) is gradually reduced. FIG. 2a is a schematic perspective view of a molding device (1) in a second manufacturing step based on some embodiments of the present invention. FIG. 2b is a side view of the molding device (1) of FIG. 2a. As illustrated in FIGS. 2a and 2b, relative movement occurs between the upper mold (2) and the lower mold (3). In some embodiments, the position of the upper mold (2) may be fixed, and the lower mold (3) and the intermediate mold (4) may be moved toward the upper mold (2). In some embodiments, the positions of the lower mold (3) and the intermediate mold (4) may be fixed, and the upper mold (2) may be moved toward the lower mold (3) and the intermediate mold (4). In some embodiments, the lower mold (3) and the upper mold (2) may be moved toward each other. In the steps shown in FIGS. 2a and 2b, the intermediate mold (4) is in contact with the upper mold (2), but the lower mold (3) is not yet in contact with the upper mold (2). That is, the intermediate mold (4) contacts the upper mold (2) before the lower mold (3) contacts the upper mold (2). For example, the intermediate mold (4) may be introduced into the concave portion (23) of the upper mold (2). The first inner surface (231) of the upper mold (2) may be in contact with the upper surface of the intermediate mold (4) (including the upper surface (421) of the upper mold (42) and the upper surface (411) of the main body portion (41). The second inner surface (232) of the upper mold (2) may come into contact with the outer surface (423) of the intermediate mold (4). In some embodiments, the lower surface of the intermediate mold (4) (including the lower surface (422) of the upper mold (42) and the lower surface (412) of the main body part (41)) may be substantially the same plane as the lower surface (22) of the upper mold (2).Meanwhile, the gap (G) between the upper surface (31) of the lower mold (3) and the lower surface of the intermediate mold (4) is not changed.

[0031] As illustrated in FIGS. 3a and 3b, the relative movement between the upper mold (2) and the lower mold (3) continues until the distance between the upper mold (2) and the lower mold (3) is reduced to zero. FIG. 3a is a schematic perspective view of a molding device (1) in a third manufacturing step based on some embodiments of the present invention. FIG. 3b is a side view of the molding device (1) of FIG. 3a. In some embodiments, the position of the upper mold (2) may be fixed, the intermediate mold (4) may support the upper mold (2), and the lower mold (3) may move toward the upper mold (2). In some embodiments, the position of the lower mold (3) may be fixed, and the upper mold (2) and the intermediate mold (4) may be moved toward the lower mold (3). In some embodiments, the lower mold (3) and the upper mold (2) may be moved toward each other. Accordingly, the gap (G) between the upper surface (31) of the lower mold (3) and the lower surface of the intermediate mold (4) is reduced to zero. The upper mold (2) may be driven to apply a downward force to the intermediate mold (4) to move the intermediate mold (4) downward and compress the elastic mechanism (52). Accordingly, elastic potential energy is accumulated in the compressed elastic mechanism (52).

[0032] As illustrated in FIGS. 3a and 3b, the molding device (1) is configured in a closed manner, and the upper mold (2) is engaged with the lower mold (3). The lower surface (22) of the upper mold (2) and the lower surface (412) of the main body (41) may come into contact with the upper surface (31) of the lower mold (3). Accordingly, the upper mold (2) and the lower mold (3) may jointly define a receiving space (12) for introducing the intermediate mold (4). It can be understood that the receiving space (12) may be substantially identical to the concave portion (23) of the upper mold (2). The entire intermediate mold (4) is placed and received within the receiving space (12). Additionally, the upper mold (2), the intermediate mold (4), and the lower mold (3) may jointly define a mold cavity (14). The mold cavity (14) is configured to receive material, and the material can be produced into a molded product having a predetermined shape by mold molding. The passage (24) of the upper mold (2) is connected to the mold cavity (14). In some embodiments, the opening (241) of the passage (24) may be connected to an injection molding machine or an extrusion molding machine, and the material may be injected / extruded from the injection molding machine or the extrusion molding machine into the mold cavity (14) to form a predetermined shape.

[0033] As illustrated in FIGS. 3a and 3b, the mold cavity (14) may include a first part (141) and a second part (142) that are in communication with each other. The first part (141) may be defined by the second inner surface (232) of the upper mold (2) and the side wall of the concave part (43) of the upper mold (42). It can be understood that the first part (141) of the mold cavity (14) may be substantially identical to the concave part (43) of the upper mold (42). Additionally, the second part (142) may be defined by the side wall of the concave portion (33) of the lower mold (3), the lower surface of the intermediate mold (4) (including the lower surface (422) of the protruding mold (42) and the lower surface (412) of the main body portion (41)), and the lower surface (22) of the upper mold (2). It can be understood that the second part (142) of the mold cavity (14) may be substantially identical to the concave portion (33) of the lower mold (3).

[0034] As illustrated in FIGS. 4a and 4b, a material (60) may be injected into the mold cavity (14) through the opening (241) of the passage (24). The material (60) may at least partially surround the intermediate mold (4). FIG. 4a is a schematic perspective view of a molding device (1) in a fourth manufacturing step based on some embodiments of the present invention. FIG. 4b is a side view of the molding device (1) of FIG. 4a. In some embodiments, the material (60) is injected into the mold cavity (14) when the molding device (1) is in a closed configuration, or when the upper mold (2) and the lower mold (3) are interlocked with each other. In some embodiments, the material (60) may include thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or other suitable materials. In some embodiments, the material (60) is a foamed material or a low-foaming material. In some embodiments, the material (60) is a non-foaming material. In some embodiments, the material (60) may completely fill the mold cavity (14) (including the first part (141) and the second part (142)).

[0035] After that, a molded product (6) is integrally formed from the material (60). The molded product (6) may be a shoe such as a slipper, flip-flop, or sandal. The molded product (6) may include a base portion (62) (e.g., a sole portion) and at least one upper portion (61) (e.g., a strap portion). The upper portion (61) of the molded product (6) may be formed from the first portion of the material (60) placed within the first portion (141) of the mold cavity (14). The base portion (62) of the molded product (6) may be formed from the second portion of the material (60) placed within the second portion (142) of the mold cavity (14). Additionally, an additional pin (63) may be formed from the third portion of the material (60) placed within the passage (24). The additional pin (63) may be connected to the upper part (61) of the molded product (6).

[0036] As illustrated in FIGS. 5A and 5B, the lower mold (3) is separated from the upper mold (2). FIG. 5A is a schematic perspective view of a molding device (1) in a fifth manufacturing step based on a partial embodiment of the present invention. FIG. 5B is a side view of the molding device (1) of FIG. 5A. Relative movement occurs between the upper mold (2) and the lower mold (3), and the distance between the upper mold (2) and the lower mold (3) gradually increases. At the same time, the molded product (6) may be retained, supported, or installed in the intermediate mold (4), and the additional pin (63) may be installed in the molded product (6). In some embodiments, the position of the upper mold (2) may be fixed, and only the lower mold (3) may be moved away from the upper mold (2). At the same time, the intermediate mold (4) may support the upper mold (2) and prevent it from moving. Relative movement between the intermediate mold (4) and the lower mold (3) may be achieved by a compressive force applied to the intermediate mold (4) by the position control mechanism (5). This compressive force is converted from the elastic potential energy accumulated in the compressed elastic mechanism (52) of FIGS. 3a and FIGS. 3b.

[0037] In some embodiments, the position of the lower mold (3) may be fixed, and the upper mold (2) and the intermediate mold (4) may be moved simultaneously away from the lower mold (3). At the same time, the intermediate mold (4) may support the upper mold (2) and move together with the upper mold (2). Relative movement between the intermediate mold (4) and the lower mold (3) may be achieved by a compressive force applied to the intermediate mold (4) by the position control mechanism (5). This compressive force is converted from the elastic potential energy accumulated in the compressed elastic mechanism (52) of FIGS. 3a and FIGS. 3b.

[0038] As illustrated in FIGS. 6a and 6b, the relative movement between the upper mold (2) and the lower mold (3) continues until the upper mold (2) is separated from the intermediate mold (4). FIG. 6a is a schematic perspective view of a molding device (1) in the sixth manufacturing step based on some embodiments of the present invention. FIG. 6b is a side view of the molding device (1) of FIG. 6a. Meanwhile, the molded product (6) may remain on the intermediate mold (4). In some embodiments, since the position of the upper mold (2) is fixed and the maximum displacement of the intermediate mold (4) is limited by the position control mechanism (5) installed on the lower mold (3), the lower mold (3) and the intermediate mold (4) may be moved simultaneously away from the upper mold (2). In some embodiments, the position of the lower mold (3) may be fixed, and the upper mold (2) may be moved away from the lower mold (3) and the intermediate mold (4). As shown in FIG. 6b, the distance between the intermediate mold (4) and the upper mold (2) may be greater than the distance between the intermediate mold (4) and the lower mold (3).

[0039] As illustrated in FIG. 7, the molded product (6) may be released from the upper side of the intermediate mold (4). FIG. 7 is a schematic perspective view of a molding device (1) in the seventh manufacturing step based on an embodiment of some of the present invention. As illustrated in FIG. 7, the molded product (6) may be released from the intermediate mold (4) through the space between the intermediate mold (4) and the upper mold (2). It can be understood that the gap (G) between the upper surface (31) of the lower mold (3) and the lower surface of the intermediate mold (4) can facilitate the release of the molded product (6).

[0040] After that, by removing the additional pin (63) from the molded product (6), the molded product (6) shown in FIG. 8 can be obtained.

[0041] FIG. 8 is a schematic perspective view of the molded article (6) based on an embodiment of some of the present invention. The molded article (6) may include a base portion (62) and at least one upper portion (61) connected to the base portion (62). The base portion (62) and the upper portion (61) may be formed simultaneously as a single unit. Therefore, there may be no interface between the base portion (62) and the upper portion (61).

[0042] FIGS. 9 to 15 illustrate a molding method for manufacturing a molded article based on some embodiments of the present invention. In some embodiments, the method is for manufacturing the molded article (6) shown in FIG. 8.

[0043] As illustrated in FIG. 9, a molding device (1a) is provided. The molding device (1a) of FIG. 9 is similar to the molding device (1) of FIG. 1a and FIG. 1b, but the intermediate mold (4a) is reversed vertically. The molding device (1a) may include an upper mold (2a), a lower mold (3a), an intermediate mold (4a), and a position control mechanism (5a). In the embodiment illustrated in FIG. 9, the molding device (1a) is configured as an open structure.

[0044] The upper mold (2a) may have an upper surface (21) and a lower surface (22) positioned opposite the upper surface (21). The upper mold (2a) may define a concave portion (23a) and at least one passage (24). The lower surface (22) of the upper mold (2a) may face the lower mold (3a) and the intermediate mold (4a). The concave portion (23a) of the upper mold (2a) may be recessed from the lower surface (22) of the upper mold (2a). The configuration (e.g., dimensions or shape) of the concave portion (23a) of the upper mold (2a) may correspond to the configuration (e.g., dimensions or shape) of the upper surface (421) of the intermediate mold (4a). The location of the corresponding concave portion (23a) of the corresponding upper mold (2a) may be directly above the corresponding intermediate mold (4a). The corresponding concave portion (23a) of the corresponding upper mold (2a) in FIG. 9 may be similar to the corresponding concave portion (33) of the corresponding lower mold (3) in FIG. 1a and FIG. 1b.

[0045] In some embodiments, the passage (24) may be extended through the upper mold (2a) or may have an opening (241) on the upper surface (21) of the upper mold (2a). In some embodiments, when the molding device (1a) is configured as a closed structure as shown in FIG. 11, the passage (24) may be in communication with the concave portion (23a) of the upper mold (2a) or the mold cavity (14a). Alternatively, the passage (24) may be in communication with the concave portion (23a) of the upper mold (2a). Thus, the concave portion (23a) of the upper mold (2a) may be accessible through the passage (24).

[0046] The lower mold (3a) may be positioned below the upper mold (2a). The lower mold (3a) may have an upper surface (31) and a lower surface (not shown) positioned on the opposite side of the upper surface (31). The lower mold (3a) may have a concave portion (33a) and a hole structure (34a). The upper surface (31) of the lower mold (3a) may face the upper mold (2a) and the intermediate mold (4a). The concave portion (33a) of the lower mold (3a) may be concavely sunken from the upper surface (31a) of the lower mold (3a).

[0047] The configuration (e.g., dimensions or shape) of the concave portion (33a) of the lower mold (3a) may correspond to the configuration (e.g., dimensions or shape) of the intermediate mold (4a). The concave portion (33a) of the lower mold (3a) may be part of the mold cavity (14a) when the molding device (1a) is in a closed configuration as shown in FIG. 11. The concave portion (33a) of the lower mold (3a) may include a first inner surface (331a) and a second inner surface (332a). The second inner surface (332a) may be extended between the first inner surface (331a) and the upper surface (31) of the lower mold (3a). The first inner surface (331a) and the second inner surface (332a) may substantially follow the shape of the intermediate form (4a). The concave portion (33a) of the lower form (3a) of FIG. 9 may be similar to the concave portion (23) of the upper form (2) of FIG. 1a and FIG. 1b.

[0048] In some embodiments, the hole structure (34a) may be positioned below the concave portion (33a) of the lower mold (3a) and may be in communication with the concave portion (33a) of the lower mold (3a). In some embodiments, the hole structure (34a) may be used to introduce at least a part of the position control mechanism (5a).

[0049] The intermediate mold (4a) may be positioned between the upper mold (2a) and the lower mold (3a) and may be movably installed in the lower mold (3a) through the position control mechanism (5a). The intermediate mold (4a) may be movable between the upper mold (2a) and the lower mold (3a) by operating the position control mechanism (5a). In some embodiments, the position control mechanism (5a) may drive or operate the intermediate mold (4a) to move it along the direction between the upper mold (2a) and the lower mold (3a) or along the height of the molding device (1a). It may be understood that the maximum displacement amount of the intermediate mold (4a) is limited by the position control mechanism (5a). That is, the gap or distance between the intermediate type (4a) and the lower type (3a) is controlled by the position control mechanism (5a). Also, the gap or distance between the intermediate type (4a) and the upper type (2a) is not controlled by the position control mechanism (5a).

[0050] The intermediate type (4a) of FIG. 9 may be similar to the intermediate type (4) of FIG. 1a and FIG. 1b, but the main body part (41) of FIG. 1a and FIG. 1b may be omitted, and the intermediate type (4a) of FIG. 9 differs in that it is vertically opposite. As shown in FIG. 9, the intermediate type (4a) may include a spherical shape (42). The spherical shape (42) may have an upper surface (421), a lower surface (422) positioned opposite the upper surface (421), and an outer surface (423) extending between the upper surface (421) and the lower surface (422). Additionally, the spherical shape (42) may define at least one concave part (43) that is concavely sunken from the outer surface (423). The concave portion (43) of the intermediate type (4a) may be part of the mold cavity (14a) when the molding device (1a) is configured as a closed structure as shown in FIG. 11.

[0051] The position control mechanism (5a) may be connected to or installed on the lower surface (422) of the intermediate type (4a) and the lower surface (422) of the lower type (42). The position control mechanism (5a) drives or operates the intermediate type (4a) upward, and when the molding device (1a) is in an open configuration, it can create a gap (G) between the upper surface (31) of the lower type (3a) and the lower surface (422) of the lower type (42). That is, the position control mechanism (5a) can create relative movement between the intermediate type (4a) and the lower type (3a). As shown in FIG. 9, when the molding device (1a) is in an open configuration, the gap (G) reaches a maximum value.

[0052] In some embodiments, a part of the position control mechanism (5a) may be introduced into the hole structure (34a) of the lower mold (3a). Accordingly, when the molding device (1a) is in a closed configuration, the entire position control mechanism (5a) may be introduced into the hole structure (34a) of the lower mold (3a).

[0053] As illustrated in FIG. 9, the position control mechanism (5a) may include an ejector (51), an elastic mechanism (52), and a fixed support (53). The ejector (51) may be a pin, a support, a post, or a columnar body, and may be used to guide the direction of movement of the intermediate type (4a). The upper end of the ejector (51) may be connected to or installed on the lower surface (422) of the foot shape (42) of the intermediate type (4a), and the lower end of the ejector (51) may be extended into the hole structure (34a) and slide within the hole structure (34a). The elastic mechanism (52) may be used to control the movement of the ejector (51) or to drive the ejector (51). For example, the elastic mechanism (52) may be a spring or an elastic body placed in the hollow portion in the center of the ejector (51). The upper end of the elastic mechanism (52) may be connected to or installed on the lower surface (422) of the foot shape (42) of the intermediate shape (4a), and the lower end of the elastic mechanism (52) may be connected to or installed on the fixed support (53). When a downward force is applied to the intermediate shape (4a) to move the intermediate shape (4a) downward and drive it to press the elastic mechanism (52), elastic potential energy is accumulated in the pressed elastic mechanism (52). When the downward force is released, the intermediate shape (4a) is pressed upward by the elastic potential energy. It is understood that the position control mechanism (5a) may be a piston having a compression phase and an elastic recovery phase or other suitable mechanism. In some embodiments, the elastic mechanism (52) may be omitted, and the lower end of the ejector (51) may be connected to a suitable actuator. By doing so, the movement of the ejector (51) may not be controlled by elastic potential energy.

[0054] As illustrated in FIG. 10, the distance between the upper mold (2a) and the lower mold (3a) is gradually reduced. Relative movement occurs between the upper mold (2a) and the lower mold (3a). In some embodiments, the position of the upper mold (2a) may be fixed, and the lower mold (3a) and the intermediate mold (4a) may be moved toward the upper mold (2a). In some embodiments, the positions of the lower mold (3a) and the intermediate mold (4a) may be fixed, and the upper mold (2a) may be moved toward the lower mold (3a) and the intermediate mold (4a). In some embodiments, the lower mold (3a) and the upper mold (2a) may be moved toward each other. In the step illustrated in FIG. 10, the intermediate mold (4a) is in contact with the upper mold (2a), but the lower mold (3a) is not yet in contact with the upper mold (2a). Meanwhile, the gap (G) between the upper surface (31) of the lower mold (3a) and the lower surface (422) of the intermediate mold (4a) is not changed.

[0055] As illustrated in FIG. 11, the relative movement between the upper mold (2a) and the lower mold (3a) continues until the distance between the upper mold (2a) and the lower mold (3a) is reduced to zero. In some embodiments, the position of the upper mold (2a) may be fixed, the intermediate mold (4a) may support the upper mold (2a), and the lower mold (3a) may move toward the upper mold (2a). In some embodiments, the position of the lower mold (3a) may be fixed, and the upper mold (2a) and the intermediate mold (4a) may be moved toward the lower mold (3a). In some embodiments, the lower mold (3a) and the upper mold (2a) may be moved toward each other. Accordingly, the gap (G) between the upper surface (31) of the lower mold (3a) and the lower surface (422) of the intermediate mold (4a) is reduced to zero. The upper mold (2a) may be driven to apply a downward force to the intermediate mold (4a), thereby moving the intermediate mold (4a) downward and compressing the elastic mechanism (52). Accordingly, elastic potential energy is accumulated in the compressed elastic mechanism (52).

[0056] As illustrated in FIG. 11, the molding device (1) is configured in a closed manner, and the upper mold (2a) is engaged with the lower mold (3a). The lower surface (22) of the upper mold (2a) may come into contact with the upper surface (31) of the lower mold (3a). Accordingly, the upper mold (2a) and the lower mold (3a) may jointly define a receiving space (12a) for introducing the intermediate mold (4a). It can be understood that the receiving space (12a) may be substantially identical to the concave portion (33a) of the lower mold (3a). For example, the intermediate mold (4a) may be introduced into the concave portion (33a) of the lower mold (3a). The first inner surface (331a) of the lower mold (3a) may come into contact with the lower surface (422) of the foot shape (42) of the intermediate mold (4a). The second inner surface (332a) of the lower mold (3a) may come into contact with the outer surface (423) of the intermediate mold (4a). In some embodiments, the upper surface (421) of the foot shape (42) of the intermediate mold (4a) may be substantially the same plane as the upper surface (31) of the lower mold (3a).

[0057] Additionally, the upper mold (2a), the intermediate mold (4a), and the lower mold (3a) may jointly define a mold cavity (14a). The mold cavity (14a) is configured to receive material, and the material can be produced into a molded product having a predetermined shape by mold molding. The passage (24) of the upper mold (2a) is connected to the mold cavity (14a). In some embodiments, the opening (241) of the passage (24) may be connected to an injection molding machine or an extrusion molding machine, and the material may be injected / extruded from the injection molding machine or the extrusion molding machine into the mold cavity (14a) to form a predetermined shape.

[0058] The mold cavity (14a) of FIG. 11 may be similar to the mold cavity (14) of FIG. 1a and FIG. 1b, and may include a first part (141a) and a second part (142a) that are connected to each other. The first part (141a) may be defined by the second inner surface (332a) of the lower mold (3a) and the side wall of the concave part (43) of the shoe mold (42). It can be understood that the first part (141a) of the mold cavity (14a) may be substantially identical to the concave part (43) of the shoe mold (42). Additionally, the second part (142a) may be defined by the side wall of the concave portion (23a) of the upper mold (2a), the upper surface (421) of the protruding portion (42) of the intermediate mold (4a), and the upper surface (31) of the lower mold (3a). It can be understood that the second part (142a) of the mold cavity (14a) may be substantially identical to the concave portion (23a) of the upper mold (2a).

[0059] As illustrated in FIG. 12, a material (60) may be injected into the mold cavity (14a) through the opening (241) of the passage (24). The material (60) may at least partially surround the intermediate mold (4a). In some embodiments, the material (60) may completely fill the mold cavity (14a) (including the first part (141a) and the second part (142a)). Afterward, a molded product (6) is integrally formed from the material (60). The molded product (6) may be a shoe such as a slipper, flip-flop, or sandal. The molded product (6) may include a base part (62) (e.g., a sole part) and at least one upper part (61) (e.g., a strap part). The upper portion (61) of the molded product (6) may be formed as a first portion of the material (60) disposed within the first portion (141a) of the mold cavity (14a). The base portion (62) of the molded product (6) may be formed as a second portion of the material (60) disposed within the second portion (142a) of the mold cavity (14a). Additionally, at least one additional pin (63) may be formed as a third portion of the material (60) disposed within the passage (24). The additional pin (63) may be connected to the base portion (62) of the molded product (6).

[0060] As illustrated in FIG. 13, the lower mold (3a) is separated from the upper mold (2a). Relative movement occurs between the upper mold (2a) and the lower mold (3a), and the distance between the upper mold (2a) and the lower mold (3a) gradually increases. At the same time, the molded product (6) may be retained, supported, or installed in the intermediate mold (4a), and the additional pin (63) may be installed in the molded product (6). In some embodiments, the position of the upper mold (2a) may be fixed, and only the lower mold (3a) may be moved away from the upper mold (2a). At the same time, the intermediate mold (4a) may support the upper mold (2a) and not move. The relative movement between the intermediate type (4a) and the lower type (3a) may be achieved by a compressive force applied to the intermediate type (4a) by the position control mechanism (5a). This compressive force is converted from the elastic potential energy accumulated in the compressed elastic mechanism (52) of FIG. 11.

[0061] In some embodiments, the position of the lower mold (3a) may be fixed, and the upper mold (2a) and the intermediate mold (4a) may be moved simultaneously away from the lower mold (3a). At the same time, the intermediate mold (4a) may support the upper mold (2a) and move together with the upper mold (2a). Relative movement between the intermediate mold (4a) and the lower mold (3a) may be achieved by a compressive force applied to the intermediate mold (4a) by the position control mechanism (5a). This compressive force is converted from the elastic potential energy accumulated in the compressed elastic mechanism (52) of FIG. 11.

[0062] As illustrated in FIG. 14, the relative movement between the upper mold (2a) and the lower mold (3a) continues until the upper mold (2a) is separated from the intermediate mold (4a). Meanwhile, the molded product (6) may remain on the intermediate mold (4a). In some embodiments, the position of the upper mold (2a) is fixed, and the maximum displacement of the intermediate mold (4a) is limited by the position control mechanism (5a) installed on the lower mold (3a), so the lower mold (3a) and the intermediate mold (4a) may be moved simultaneously away from the upper mold (2a). In some embodiments, the position of the lower mold (3a) is fixed, and the upper mold (2a) may be moved away from the lower mold (3a) and the intermediate mold (4a). As shown in FIG. 14, the distance between the intermediate type (4a) and the upper type (2a) may be greater than the distance between the intermediate type (4a) and the lower type (3a).

[0063] As illustrated in FIG. 15, the molded product (6) may be released from the upper side of the intermediate mold (4a). As illustrated in FIG. 15, the molded product (6) may be released from the intermediate mold (4a) through the space between the intermediate mold (4a) and the upper mold (2a). It can be understood that the gap (G) between the upper surface (31) of the lower mold (3a) and the lower surface (422) of the intermediate mold (4a) can facilitate the release of the molded product (6).

[0064] After that, by removing the additional pin (63) from the molded product (6), the molded product (6) shown in FIG. 8 can be obtained.

[0065] FIGS. 16a to 20 illustrate a molding method for manufacturing a molded article based on some embodiments of the present invention. In some embodiments, the method is for manufacturing the molded article (6) shown in FIG. 8.

[0066] As illustrated in FIGS. 16a and 16b, a molding device (1b) is provided. The molding device (1b) of FIGS. 16a and 16b is similar to the molding device (1) of FIGS. 1a and 1b, but differs in that the spherical shape (42) of the intermediate shape (4b) may also be concavely recessed from the outer surface (423) and may define at least one engraving hole (44) and an opening (45) that communicate with the concave portion (43). The position of the passage (24) of the upper shape (2) may correspond to the opening (45). The depth of the engraving hole (44) may be smaller than the depth of the concave portion (43). The depth of the opening (45) may be larger than the depth of the engraving hole (44) and the depth of the concave portion (43).

[0067] As shown in FIG. 17a and FIG. 17b, the molding device (1b) is configured as a closed structure. The engraved opening (44), the opening (45), and the recess (43) of the intermediate mold (4b) may be part of the mold cavity (14).

[0068] As illustrated in FIGS. 18a and 18b, a material (60) may be injected into the mold cavity (14) through the opening (241) of the passage (24). Afterward, a molded product (6) is integrally formed from the material (60). The molded product (6) may include a base portion (62) (e.g., a sole portion), at least one upper portion (61) (e.g., a strap portion), at least one strip (64), and a protrusion (65). Additionally, at least one additional pin (63) may be formed on the protrusion (65). That is, the protrusion (65) may be located below the additional pin (63). Additionally, the base portion (62), the upper portion (61), the strip (64), the projection portion (65), and the additional pin (63) may be formed simultaneously as a single unit. The upper portion (61) may be connected to the base portion (62). The additional pin (63) may be connected to the strip (64), and the strip (64) may be connected to the upper portion (61). The thickness of the projection portion (65) may be greater than the thickness of the strip (64) and the thickness of the upper portion (61). The thickness of the strip (64) may be smaller than the thickness of the upper portion (61).

[0069] As shown in FIG. 19a and FIG. 19b, the lower mold (3) is detached from the upper mold (2).

[0070] As shown in FIG. 20, the molded product (6) may be molded from the upper side of the intermediate mold (4b).

[0071] After that, the molded product (6) shown in FIG. 8 can be obtained by removing the additional pin (63), the protrusion (65), and the strip (64) from the molded product (6). In some embodiments, the additional pin (63), the protrusion (65), and the strip (64) are removed from the molded product (6) by cutting or shearing the strip (64).

[0072] FIG. 21 is a flowchart illustrating a molding method based on some embodiments of the present invention. As shown in FIG. 21, the molding method (70) may include the following steps.

[0073] In some embodiments, the molding method (70) may include a process S71 that provides a lower mold and an intermediate mold movably installed in the lower mold. For example, as shown in FIGS. 1a and FIGS. 1b, a molding device (1) is provided. The molding device (1) may include an upper mold (2), a lower mold (3), an intermediate mold (4), and a position control mechanism (5). The intermediate mold (4) may be movably installed in the lower mold (3) through the position control mechanism (5).

[0074] In some embodiments, the molding method (70) may include a process S72 in which the upper mold is coupled with the lower mold to define a receiving space, the intermediate mold is placed within the receiving space, and the upper mold, the intermediate mold, and the lower mold jointly define a mold cavity. For example, as shown in FIGS. 3a and 3b, the upper mold (2) is coupled with the lower mold (3) to define a receiving space (12), and the intermediate mold (4) is placed within the receiving space (12). The upper mold (2), the intermediate mold (4), and the lower mold (3) jointly define a mold cavity (14).

[0075] In some embodiments, the molding method (70) may include a process S73 of injecting a material into the mold cavity and at least partially surrounding the intermediate mold. For example, as shown in FIGS. 4a and 4b, a material (60) is injected into the mold cavity (14), and the material (60) at least partially surrounds the intermediate mold (4).

[0076] In some embodiments, the molding method (70) may include a process S74 for forming a molded article with the material. For example, as shown in FIG. 4a and FIG. 4b, a molded article (6) is formed with the material (60).

[0077] The foregoing description outlines the features of several embodiments to enable those skilled in the art to better understand the embodiments of the present invention. Those skilled in the art may use the present invention as a basis and design or modify other processes and structures to perform the same purpose 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 essence and scope of the present invention, and that various modifications, substitutions, and alterations of the present invention are possible without departing from the essence and scope of the present invention.

[0078] Furthermore, the scope of the present invention is not limited to specific embodiments of the process, machine, manufacture, composition of material, means, method, and steps described herein. As will be readily understood by those skilled in the art from the disclosure of the present invention, the process, machine, manufacture, composition of material, means, method, or step achieves substantially the same result as the corresponding embodiments described herein that are currently existing or subsequently developed, or that perform substantially the same function or are available according to the present invention. Accordingly, the appended claims are intended to include such processes, machines, manufacture, composition of material, means, method, and steps within their scope. Explanation of the symbols

[0079] 1, 1a, 1b: Forming device 12, 12a: Reception space 14, 14a: Mold cavity 141, 141a: Part 1 142, 142a: Part 2 2, 2a: pictograph 21: Top surface 22: If 23, 23a: Concave part 24: Passage 241: Opening 3, 3a: Lower form 31, 31a: Top surface 33, 33a: Concave part 331a: First inner surface 332a: Second inner surface 34, 34a: Hole structure 341: The first hole 342: The second hole 343: Step structure 4, 4b: intermediate form 41: Main body 411: Top surface 412: If 42: Oral form 421: Top surface 422: If 423: Turning Away 43: Concave part 44: Engraved Eye 45: Opening 5, 5a: Position control mechanism 51: Ejector 52: Elastic mechanism 53: Fixed support 6: Molded product 60: Ingredients 61: Upper part 62: Bass part 63: Additional Pins 64: Strip 65: Protrusion 70: Plastic surgery methods G: Gap S71, S72, S73, S74: Process

Claims

Claim 1 A molding device comprising: an upper surface, a lower surface opposite to the upper surface, and an upper die having a concave portion defined from the lower surface toward the inner surface of the upper die disposed between the upper surface and the lower surface, and a passage including an end portion extending through the upper die and configured to be coupled to an injection molding machine; a lower die disposed below the upper die; and a hole structure extending into the lower die. A molding apparatus comprising an intermediate form disposed between the upper mold and the lower mold and movably installed in the lower mold through a position control mechanism, wherein the position control mechanism includes an ejector and an elastic mechanism, wherein a first end of the ejector is installed on the lower surface of the intermediate form and a second end extends into a hole structure, wherein when the lower surface of the upper mold contacts the lower mold, the upper surface of the intermediate form contacts the inner surface of the upper mold, and the position control mechanism is completely disposed below the lower surface of the intermediate form on the opposite side of the upper surface of the intermediate form, and wherein the mold cavity defined by the upper mold, the intermediate form, and the lower mold is capable of communicating with the other opposite end of the passage when the upper mold is engaged with the lower mold and the intermediate form is surrounded by the upper mold and the lower mold. Claim 2 A molding device according to claim 1, characterized in that when the molding device is in a closed configuration, the upper mold and the lower mold define a receiving space for introducing the intermediate mold. Claim 3 A molding device according to claim 1, characterized in that the hole structure is not vertically aligned with the passage. Claim 4 A molding device according to claim 1, wherein the position control mechanism is connected to the lower surface of the intermediate mold, and is completely surrounded by the intermediate mold and the lower mold when the upper mold is engaged with the lower mold. Claim 5 A molding device according to claim 1, characterized in that the position control mechanism comprises at least one ejector connected to the intermediate type and an elastic mechanism for controlling the movement of the ejector. Claim 6 A molding method comprising: (a) a process of providing an upper die, a lower die, and an intermediate die movably installed in the lower die through a position control mechanism, wherein the upper die defines an upper surface, a lower surface opposite to the upper surface, a concave portion recessed from the lower surface toward the inner surface of the upper die disposed between the upper surface and the lower surface, and a passage extending through the upper die from the upper surface to the inner surface, wherein the position control mechanism is completely disposed below the lower surface of the intermediate die and includes an ejector and an elastic mechanism, wherein a first end of the ejector is installed on the lower surface of the intermediate die and a second end extends into a hole structure of the lower die; (b) a process of defining a receiving space by engaging the upper die with the lower die, wherein the intermediate die is disposed within the receiving space, and wherein the upper die, the intermediate die, and the lower die define a mold cavity, wherein the mold cavity is communicable with the passage, and the upper surface of the intermediate die contacts the inner surface of the upper die before the lower die contacts the upper die; and (c) the passage A molding method characterized by comprising: a process of joining to an injection molding machine; (d) a process of injecting material into a mold cavity through a passage from the injection molding machine and at least partially surrounding the intermediate mold; and (e) a process of forming a molded article with the material. Claim 7 A molding method according to claim 6, further comprising (f) a process of separating the lower mold from the upper mold and (g) a process of separating the upper mold from the intermediate mold. Claim 8 A molding method according to claim 7, further comprising (h) a process of releasing the molded product from the upper side of the intermediate type. Claim 9 A molding method according to claim 8, wherein in the above process (e), the molded article comprises a base portion, at least one upper portion, at least one strip, and an additional pin, wherein the upper portion is connected to the base portion, the strip is connected to the upper portion, and the additional pin is connected to the strip. Claim 10 A molding method according to claim 9, characterized by further including (i) a process of removing the additional pin and the strip.

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