CN117863431A

CN117863431A - Injection molding system and injection molding method

Info

Publication number: CN117863431A
Application number: CN202311264382.4A
Authority: CN
Inventors: 陈璟浩; 叶良辉
Original assignee: King Steel Machinery Co Ltd
Current assignee: King Steel Machinery Co Ltd
Priority date: 2022-10-12
Filing date: 2023-09-27
Publication date: 2024-04-12

Abstract

The invention discloses an injection molding system, comprising: a supply unit configured to supply a flowable mixture; an injection unit communicable with the supply unit, wherein the injection unit includes an outlet configured to discharge the flowable mixture; a forming device configured to receive the flowable mixture from the outlet and comprising a mold cavity and a feed port communicable with the mold cavity and engaged with the outlet; and a support device disposed between the injection unit and the molding device and configured to facilitate engagement of the injection unit and the molding device. The support device comprises a first element connected to the injection unit and a second element arranged on the forming device. The second element includes a groove configured to receive a protruding portion of the first element, the protruding portion of the first element being slidable within and along the groove of the second element.

Description

Injection molding system and injection molding method

Cross reference to related applications

The present application claims priority to U.S. provisional application Ser. No. 63/379,255, filed on Ser. No. 10/12 at 2022, and U.S. patent application Ser. No. 18/451,073, filed on 8/16 at 2023, the disclosures of both of which are incorporated herein by reference in their entireties.

Technical Field

The present invention relates to an injection molding system and an injection molding method, and more particularly, to an injection molding system and an injection molding method for manufacturing foamed polymer products.

Background

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

Disclosure of Invention

An object of the present invention is to provide an injection molding system and an injection molding method.

According to one embodiment of the present invention, an injection molding system is disclosed. The injection molding system includes: a supply unit configured to supply a flowable mixture of a polymeric material and a blowing agent; an injection unit communicable with the supply unit, wherein the injection unit includes an outlet disposed remote from the supply unit and configured to discharge the flowable mixture; a forming device configured to receive the flowable mixture from the outlet and comprising a mold cavity and an opening communicable with the mold cavity and correspondingly engaged with the outlet; and a support device configured to facilitate engagement of the injection unit and the molding device. The support device comprises a first element connected to the injection unit and a second element arranged on the forming device. The second element includes a groove configured to receive a protruding portion of the first element, the protruding portion of the first element being slidable within and along the groove of the second element.

According to one embodiment of the present invention, an injection molding method is disclosed. The molding method comprises the following steps: providing an injection molding system, wherein the injection molding system comprises an injection unit and the molding device, the injection unit comprising an outlet configured to discharge flowable material, and the molding device being configured to receive the flowable material from the outlet and comprising a mold cavity and an opening communicable with and correspondingly engaged with the mold cavity; providing a support device configured to facilitate engagement of the injection unit with the molding device, wherein the support device comprises a first element connected to the injection unit and a second element disposed on the molding device; aligning the protruding portion of the first element with the groove of the second element; moving the molding device toward the injection unit to slide the protruding portion of the first member along the groove of the second member; engaging the outlet with the opening when the protruding portion of the first element is engaged with the groove of the second element; and injecting the flowable material into the mold cavity.

Brief description of the drawings

The aspects of the invention are best understood from the following detailed description when read with the accompanying drawing figures. It should be noted that the various components are not drawn to scale according to industry standard practice. In fact, the dimensions of the various features may be arbitrarily expanded or reduced for clarity of discussion.

FIG. 1 is a schematic diagram of an injection molding system according to some embodiments of the present invention.

Fig. 2 is a schematic diagram illustrating a portion of an injection molding system according to some embodiments of the invention.

Fig. 3 is a schematic top view illustrating a portion of an injection molding system according to some embodiments of the present invention.

Fig. 4 is a schematic diagram illustrating a portion of an injection molding system according to some embodiments of the invention.

Fig. 5 is a schematic cross-sectional view illustrating a portion of an injection molding system according to some embodiments of the invention.

Fig. 6 is a flow chart illustrating an injection molding method according to some embodiments of the invention.

Fig. 7-18 are side or schematic cross-sectional views of an injection molding system at one or more injection molding process manufacturing stages according to some embodiments of the invention.

Fig. 19 is a schematic diagram of an injection molding system according to some embodiments of the invention.

Fig. 20 is a schematic diagram illustrating a portion of an injection molding system according to some embodiments of the present invention.

Fig. 21 is a schematic top view illustrating a portion of an injection molding system according to some embodiments of the present invention.

Fig. 22 is a schematic diagram illustrating a portion of an injection molding system according to some embodiments of the present invention.

Fig. 23 is a schematic cross-sectional view illustrating a portion of an injection molding system according to some embodiments of the invention.

Fig. 24 is a flowchart illustrating an injection molding method according to some embodiments of the present invention.

Fig. 25-36 are side or schematic cross-sectional views of an injection molding system at one or more injection molding process manufacturing stages according to some embodiments of the invention.

Fig. 37 is a flowchart illustrating an injection molding method according to some embodiments of the present invention.

Description of the embodiments

The following disclosure provides many different specific embodiments, or examples, for implementing different features in the provided subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. Of course, these are merely examples and are not intended to be limiting. For example, forming a first feature on or over a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present invention may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

In addition, spatially relative terms, such as "beneath," "below," "beneath," "over," and the like, may be used herein to facilitate a description of one element or feature relative to another element or feature as illustrated in the figures. Such spatially relative terms also encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. In addition, as used herein, the term "about" generally refers to within 10%, 5%, 1% or 0.5% of a known value or range. Alternatively, the term "about" when considered by a skilled artisan means within an acceptable standard error of the average. Except in the operating/working examples, or where otherwise explicitly indicated, all numerical ranges, amounts, values, and percentages disclosed herein, e.g., amounts of materials, durations, temperatures, operating conditions, ratios of amounts, and the like, are to be understood as modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the present specification and attached claims are approximations that may vary as desired. At the very least, each numerical parameter should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Ranges can be expressed herein as from one endpoint to another endpoint, or between two endpoints. Unless otherwise indicated, all ranges disclosed herein include endpoints.

Generally, the appearance and physical properties of the foamed polymer article are directly affected by the injection molding process, and therefore the injection molding system must be designed with consideration given to the injection conditions of the flowable mixture from the injection unit into the molding apparatus so as to enable the flowable mixture to be completely and effectively injected into the molding apparatus to form a foamed polymer article having the desired quality.

Fig. 1 illustrates a schematic perspective view of a first injection molding system 100, according to one embodiment of the present invention. In some embodiments, referring to fig. 1, a first injection molding system 100 includes an injection unit 101 and a molding apparatus 102. The injection unit 101 may be engaged with the molding device 102. In some embodiments, the first injection molding system 100 further includes a flowable mixture supply unit 103 that can be in communication with the injection unit 101. In some embodiments, the flowable mixture supply unit 103 is configured to generate and supply a flowable mixture to the injection unit 101.

In some embodiments, the flowable mixture includes a polymeric material, such as ethylene vinyl acetate (Ethylene vinyl acetate, EVA), styrene-ethylene-butylene-Styrene (SEBS), thermoplastic polyurethane (Thermoplastic polyurethanes, TPU), thermoplastic polyester elastomer (Thermoplastic polyester elastomer, TPEE), and the like. In some embodiments, the flowable mixture includes a recyclable material. In some embodiments, the flowable mixture further comprises a foaming agent. In some embodiments, the foaming agent may be any type of chemical or physical foaming agent known to those skilled in the art. In some embodiments, the foaming 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 flowable mixture comprises a polymeric material in a molten state, and a foaming agent in a liquid or supercritical fluid state mixed with the polymeric material. In some embodiments, the flowable mixture is a molding material.

In some embodiments, the flowable mixture supply unit 103 of the first injection molding system 100 includes an extruder (not shown) for converting the polymeric material into a molten state, and a mixer (not shown) for mixing the foaming agent into the polymeric material. The polymeric material may flow from the extruder into the mixer.

In some embodiments, the ejector unit 101 includes an ejector 101a. In some embodiments, more than one injector 101a may be included in the injection unit 101. In some embodiments, the ejector 101a is configured to receive the flowable mixture from the flowable mixture supply unit 103 and to discharge the flowable mixture from the outlet 101 c. In some embodiments, the ejector 101a is in the configuration of a discharge channel, and the outlet 101c is disposed at the distal end of the ejector 101a and is configured to discharge the flowable mixture.

In some embodiments, the injector 101a may be in communication with a mixer or flowable mixture supply unit 103. In some embodiments, the flowable mixture is discharged from the ejector 101a into the forming device 102. The ejector 101a may be engaged with the molding apparatus 102. The ejector 101a may extend toward the molding device 102 and may retract from the molding device 102. In some embodiments, ejector 101a may be vertically extended/retracted in a first direction as indicated by arrow a. In some embodiments, the injector 101a may be extended/retracted by a hydraulic mechanism 101 e. In some embodiments, hydraulic mechanism 101e is attached to injector 101a. In some embodiments, a hydraulic mechanism 101e is disposed between the flowable mixture supply unit 103 and the injector 101a.

In some embodiments, the support device 105 is configured to facilitate engagement of the injection unit 101 and the molding device 102. In some embodiments, the support device 105 is disposed above the molding device 102. In some embodiments, the support device 105 includes a first element 101b disposed adjacent the ejector 101 a. In some embodiments, the first element 101b is connected to the injection unit 101. The first element 101b may extend toward the forming device 102 and may retract from the forming device 102. In some embodiments, the first element 101B may be vertically extendable/retractable in a second direction as indicated by arrow B. In some embodiments, the first direction is parallel to the second direction.

In some embodiments, the first element 101b may be extended/retracted along the track 101f by a motor (not shown) or the like. In some embodiments, the track 101f is disposed between the flowable mixture supply unit 103 and the first element 101b. In some embodiments, the ejector 101a and the first element 101b may extend/retract independently of each other. The ejector 101a and the first element 101b are displaceable relative to each other. In some embodiments, the ejector 101a and the first element 101b may be displaced individually or together. In some embodiments, the first element 101b is T-shaped. In some embodiments, the first element 101b includes a projection 101d that is engageable with the forming device 102. In some embodiments, the protruding portion 101d of the first element 101b is arranged at the distal end of the flowable mixture supply unit 103.

In some embodiments, the injection unit 101 is disposed above the molding device 102. In some embodiments, both the ejector 101a and the first element 101b are disposed above the molding apparatus 102. In some embodiments, the forming device 102 is configured to receive the flowable mixture exiting the injector 101a through the outlet 101 c.

In some embodiments, the molding apparatus 102 includes a first mold 102c and a second mold 102d engageable with the first mold 102 c. 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) in communication with the mold cavity and correspondingly engaged with the outlet 101 c.

Fig. 2 illustrates a schematic perspective view of the second element 102s of the support device 105, and fig. 3 illustrates a schematic top view of the second element 102s. In some embodiments, referring to fig. 1-3, the support device 105 includes a second element 102s disposed on the forming device 102 and engageable with the first element 101 b. In some embodiments, the second element 102s may be engaged with the forming device 102. In some embodiments, the second element 102s may be engaged with the first mold 102 c. In some embodiments, the second element 102s is removably attached to the molding device 102. In some embodiments, the second element 102s includes a groove 102e defined by a protrusion 102 f.

In some embodiments, both the groove 102e and the protrusion 102f are laterally elongated. The groove 102e is provided to receive the protruding portion 101d of the first member 101b in the injection unit 101. The protruding portion 101d of the first element 101b may engage with the protrusion 102 f. In some embodiments, the protruding portion 101d of the first element 101b can slide within the groove 102e of the second element 102s and along the groove 102e. In some embodiments, the length L1 of the groove 102e is equal to the width W1 of the second element 102s. In some embodiments, the height H1 of the groove 102e is greater than the thickness T1 of the protruding portion 101d of the first element 101 b. In some embodiments, the protrusion 102f includes a first portion 102x and a second portion 102y, and the protruding portion 101d of the first element 101b is disposed between the first portion 102x and the second portion 102y of the protrusion 102 f.

In some embodiments, the second element 102s includes a recess 102g configured to receive the outlet 101 e. In some embodiments, the groove 102g is disposed in the second element 102s and is elongated laterally along the second element 102s. In some embodiments, groove 102g is parallel to protrusion 102f and groove 102e. In some embodiments, the groove 102g is disposed between the first portion 102x and the second portion 102y of the protrusion 102 f. The recess 102g is arranged to receive an outlet 101c or end of the ejector 101a of the ejector unit 101. The outlet 101c or end of the ejector 101a is slidable within the groove 102g and along the groove 102g. In some embodiments, the opening 102h is disposed within the recess 102g. The opening 102h extends through the second element 102s.

In some embodiments, the opening 102h receives an outlet 101c or end of the ejector 101 a. The outlet 101c or end of the ejector 101a is movable within the opening 102h. In some embodiments, the width W3 of the opening 102h is substantially greater than the width W2 of the outlet 101c of the ejector 101 a. In some embodiments, the width W3 of the opening 102h is equal to the width W2 of the outlet 101c of the ejector 101 a.

In some embodiments, the width W4 of the groove 102g is substantially greater than the width W3 of the opening 102h. In some embodiments, a step 102k is formed within the recess 102g and adjacent to the opening 102h. In some embodiments, the outlet 101c or end of the ejector 101a may be disposed on the step 102k when the forming device 102 receives the flowable mixture. In some embodiments, the width W3 of the opening 102h is substantially smaller than the width W2 of the outlet 101c of the ejector 101a, and the outlet 101c or end of the ejector 101a may be disposed on the step 102k when the outlet 101c or end of the ejector 101a is engaged with the second element 102 s. In some embodiments, the outlet 101c covers the opening 102h when the outlet 101c or end of the ejector 101a is engaged with the second element 102 s.

In some embodiments, the first sensor 102l is disposed within the groove 102e and is configured to sense contact of the protruding portion 101d of the first element 101b with the second element 102 s. In some embodiments, the first sensor 102l is disposed at a middle end of the groove 102 e. In some embodiments, the first sensor 102l is disposed within the trench 102e and adjacent to the opening 102h. The first sensor 102l is not limited to any particular type as long as it can sense pressure and provide pressure information. In some embodiments, a plurality of first sensors 102l are disposed within the groove 102e, and the first sensors 102l are configured to sense the position and contact of the protrusion 101d with the groove 102 e. The number and positions of the plurality of first sensors 102l are not particularly limited; for example, it may be disposed at any location of the protrusion 102f and within the groove 102 e; however, the present invention is not limited thereto.

In some embodiments, the second sensor 102m is disposed within the recess 102g and is configured to sense contact of the outlet 101c with the forming device 102. In some embodiments, the second sensor 102m is disposed within the recess 102g and adjacent to the opening 102h. The second sensor 102m is not limited to any particular type as long as it can sense pressure and provide pressure information. In some embodiments, a plurality of second sensors 102m are disposed within the groove 102g, and the second sensors 102m are configured to sense the position and contact of the outlet 101c with the groove 102 g. The number and positions of the plurality of second sensors 102m are not particularly limited; for example, it may be disposed anywhere in the recess 102 g; however, the present invention is not limited thereto.

In some embodiments, the forming device 102 may be in an open state and a closed state. The first mold 102c is engaged with the second mold 102d when the molding apparatus 102 is in the closed state. Fig. 4 illustrates a schematic perspective view of the molding device 102 in a closed state, and fig. 5 illustrates a schematic cross-sectional view of the molding device 102 in a closed state.

In some embodiments, referring to fig. 4 and 5, the mold cavity 102i is defined by the first mold 120c and the second mold 102d when the molding apparatus 102 is in the closed state. In some embodiments, the mold cavity 102i is configured to receive the flowable mixture from the injector 101a through the opening 102h of the second member 102 s. When the molding apparatus 102 is in the closed state, the mold cavity 102i is accessible only through the feed port 102j. When the molding apparatus 102 is in an open state, the mold cavity 102i may be accessed through a gap (not shown) between the first mold 102c and the second mold 102 d. In some embodiments, the molding apparatus 102 includes a feed port 102j that can be in communication with the mold cavity 102i. In some embodiments, the feed port 102j is disposed at the first die 102c and penetrates the first die 102c. In some embodiments, when the second element 102s is disposed over the molding device 102, the opening 102h is aligned with the feed port 102j such that a flowable mixture can flow from the injector 101a into the mold cavity 102i through the opening 102h and the feed port 102j. In some embodiments, the opening 102h overlaps the feed opening 102j when the second element 102s is disposed above the molding device 102 as viewed from a top view.

In some embodiments, the shaping device 102 is disposed on and movable with a carrier (not shown). In some embodiments, a plurality of molding devices 102 are arranged on the carrier, and the molding devices 102 are arranged in a line, row, column, arc, curve, or any other suitable configuration. In some embodiments, the carrier is rotatable.

In some embodiments, referring back to fig. 1, 2 and 3, the support device 105 further comprises a third element 101g connected to the injection unit 101, and the second element 102s is arranged to receive the first element 101b and the third element 101g. In some embodiments, the first element 101b and the third element 101g are each configured to be received by the first portion 102x and the second portion 102y of the protrusion 102 f.

In some embodiments, the third element 101g is disposed adjacent to the ejector 101 a. In some embodiments, the third element 101g is connected to the injection unit 101. In some embodiments, the ejector 101a is disposed between the first element 101b and the third element 101g. The third element 101g may be engaged with the second element 102 s. The third element 101g may be extendable toward the second element 102s and retractable from the second element 102 s. In some embodiments, the third element 101g may be vertically extendable/retractable in a second direction as indicated by arrow B.

In some embodiments, the third element 101g may be extended/retracted along the track 101f by a motor (not shown) or the like. In some specific embodiments, the track 101f is arranged between the flowable mixture supply unit 103 and the third element 101 g. In some embodiments, the third element 101g and the first element 101b may extend/retract 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 ejector 101a may extend/retract independently of each other. The third element 101g and the ejector 101a are displaceable relative to each other. In some embodiments, the third element 101g and the first element 101b may be displaced individually or together. In some embodiments, the third element 101g is T-shaped. In some embodiments, the third element 101g includes a projection 101h that is engageable with the second element 102 s. In some embodiments, the protruding portion 101h can engage with the groove 102 e. In some specific embodiments, the protruding portion 101h of the third element 101g is arranged at the distal end of the flowable 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 101 b.

In the present invention, a first injection molding method 200 is also disclosed. The first injection molding method 200 includes many operations and the description and illustration is not to be considered as limiting the order of operations. Fig. 6 shows an embodiment of a first injection molding method 200. In some embodiments, the first injection molding method 200 includes a plurality of operations (201-212). Fig. 7-18 are schematic cross-sectional views of stages of the first injection molding method according to some embodiments of the invention. In some embodiments, the first injection molding method 200 is implemented by the first injection molding system 100 as shown in fig. 1-5 and discussed above.

In operation 201, referring to fig. 7, a first injection molding system 100 including an injection unit 101, a molding apparatus 102, and a support apparatus 105 is provided. In some embodiments, the first injection molding system 100 includes an injection unit 101, a molding apparatus 102, and a support apparatus 105 as described above. The molding device 102 is in a closed state. The opening 102h of the second member 102s is aligned with the feed opening 102j of the molding apparatus 102 such that the mold cavity 102i is accessible through the opening 102h and the feed opening 102 j. In some embodiments, the shaping device 102 is disposed on and movable with a carrier (not shown). In some embodiments, a plurality of molding devices 102 are disposed on the carrier.

In operation 202, the protruding portion 101d of the first element 101b of the support device 105 is aligned with the groove 102e of the second element 102s of the support device 105. In operation 203, the outlet 101c is aligned with the groove 102g of the second element 102s configured to receive the outlet 101 c. In some embodiments, the alignment of the protruding portion 101d of the first element 101b with the groove 102e of the second element 102s and the alignment of the outlet 101c with the groove 102g are performed simultaneously. In some embodiments, the forming device 102 is disposed below the second element 102s during alignment of the protruding portion 101d of the first element 101b with the groove 102e of the second element 102 s.

In some embodiments, the ejector 101a and the first element 101B are vertically displaced along arrows a and B, respectively, to be horizontally aligned with the groove 102g and the groove 102e, respectively, as shown in fig. 7. In some embodiments, ejector 101a is moved up or down to horizontally align outlet 101c with recess 102 g. In some embodiments, the first element 101b is moved up or down to horizontally align the projection 101d with the groove 102 e. Alternatively or simultaneously, the second element 102s is displaced along arrow C and/or arrow D so as to be horizontally aligned with the protruding portion 101D of the first element 101b and the outlet 101C or end of the ejector 101 a. In some embodiments, the second element 102s is moved upward, downward, forward, or backward to horizontally align the groove 102e with the projection 101d and the groove 102g with the outlet 101c or end of the ejector 101 a.

In some embodiments, the protruding portion 101h of the third element 101g is aligned with the groove 102e of the second element 102 s. In some specific embodiments, the process of aligning the protruding portion 101h of the third element 101g with the groove 102e of the second element 102s is similar to the process of aligning the protruding portion 101d of the first element 101b with the groove 102e of the second element 102s, and duplicate descriptions are omitted for brevity. In some embodiments, the alignment of the protruding portion 101d of the first element 101b with the groove 102e of the second element 102s and the alignment of the protruding portion 101h of the third element 101g with the groove 102e are performed simultaneously.

In operation 204, referring to fig. 8 and 9, the second member 102s is displaced toward the injection unit 101 to slide the protruding portion 101d of the first member 101b along the groove 102e of the second member 102 s. In operation 205, outlet 101c slides into groove 102 g.

In some embodiments, after horizontal alignment, the second element 102s is moved toward the ejector unit 101 along arrow E, as shown in fig. 8. Alternatively, after the horizontal alignment, as shown in fig. 8, the ejection unit 101 is moved toward the second member 102s along an arrow L. In some embodiments, after the second element 102s and the injection unit 101 are horizontally aligned, the molding device 102 is moved toward the second element 102s and the injection unit 101. In other words, the molding device 102 is movable, and the injection unit 101 and the second member 102s are fixed with respect to the molding device 102.

Fig. 9 is a schematic cross-sectional view of the first injection molding system 100 of fig. 8. In some embodiments, the protruding portion 101d of the first element 101b slides along the groove 102e and the outlet 101c or end of the ejector 101a slides along the groove 102 g. In some embodiments, the protruding portion 101h of the third element 101g slides along the groove 102 e. As shown in fig. 9, the projection 102f is arranged opposite to the projection portion 101d of the first member 101 b. In some embodiments, the protruding portion 101d of the first element 101b and the protruding portion 101h of the third element 101g are both disposed between the first portion 102x and the second portion 102y of the protrusion 102 f.

In some embodiments, in operations 204 and 205, the first element 101b, the third element 101g, and the ejector 101a are not in contact with the second element 102 s. In some embodiments, the outlet 101c or end of the ejector 101a is surrounded by the groove 102g and does not contact the step 102k within the groove 102 g. In some embodiments, a first distance D1 between the bottom surface of the protrusion 101D and the second element 102s is substantially greater than a second distance D2 between the outlet 101c and the bottom surface of the recess 102 g.

In operation 206, the injection unit 101 and the support device 105 are displaced to be arranged above the molding device 102. In some embodiments, referring to fig. 10, after ejector 101a is aligned with opening 102h and ejector 101a, first element 101b is moved toward forming device 102 along arrow F, as shown in fig. 10. In some embodiments, the molding apparatus 102 is moved until the support apparatus 105 overlaps the molding apparatus 102 and the injector 101a is vertically aligned with the feed port 102j of the molding apparatus 102. In some embodiments, the forming device 102 is moved by rotating a carrier (not shown) carrying the forming device 102.

In operation 207, referring to fig. 11, the outlet 101c is extended toward the molding device 102 such that the outlet 101c is engaged with the opening 102 h.

In some embodiments, after the ejector 101a is aligned with the opening 102h, as shown in fig. 11, the ejector 101a and the first element 101b are moved toward the molding apparatus 102 along arrow F until the outlet 101c of the ejector 101a contacts the second element 102s. In some embodiments, outlet 101c engages opening 102h and contacts step 102 k. In some embodiments, the ejector 101a and the first element 101b move together. When the outlet 101c of the ejector 101a contacts the second element 102s, the entire first element 101b remains out of contact with the second element 102s, as shown in fig. 11. In some embodiments, the third element 101g (not shown in fig. 11) and the first element 101b are moved together in operation 207. In some embodiments, contact of the second element 102s and the outlet 101c is sensed by a second sensor 102m disposed within the recess 102 g. In some embodiments, the contact of the second element 102s and the outlet 101c is continuously sensed.

In operation 208, referring to fig. 12, the first element 101b is displaced away from the second element 102s while the first element 101b is received by the second element 102s. In some embodiments, the protruding portion 101d of the first element 101b is moved to abut the protrusion 102f of the second element 102s while the protruding portion 101d of the first element 101b is received by the groove 102e of the second element 102s.

In some embodiments, after the outlet 101c is in contact with the second element 102s, as shown in fig. 12, the first element 101b is moved away from the second element 102s along arrow G until the protruding portion 101d of the first element 101b contacts the protrusion 102f of the second element 102 s. In some embodiments, the ejector 101a remains stationary as the first element 101b moves upward, as shown in fig. 12. As a result, the first element 101b is engaged with the second element 102 s. In some embodiments, contact of the second element 102s and the first element 101b is sensed by a first sensor 102l disposed on the protrusion 102f and within the groove 102 e. In some embodiments, the contact of the second element 102s and the first element 101b is sensed by the first sensor 102 l. In some embodiments, the first sensor 102l senses contact of the protrusion 102f with the protruding portion 101d of the first element 101b. In some embodiments, the contact of the second element 102s and the first element 101b is sensed continuously.

In some embodiments, the third element 101g (not shown in fig. 12, shown in fig. 8) and the first element 101b are moved together in operation 208. In some embodiments, the protruding portion 101h (not shown in fig. 12, shown in fig. 8) of the third element 101g moves to abut against the protrusion 102f of the second element 102s while the protruding portion 101h of the third element 101g is received by the groove 102e of the second element 102 s. In some embodiments, contact of the protruding portion 101h of the third element 101g with the protrusion 102f of the second element 102s is sensed by the first sensor 102 l.

In operation 209, referring to fig. 13, the flowable mixture 104 is injected into the mold cavity 102i of the molding device 102.

In some embodiments, flowable mixture 104 is injected into mold cavity 102i after protrusion 101d is in contact with protrusion 102f, as shown in fig. 13. The flowable mixture 104 is discharged from the outlet 101c of the injector 101a through the opening 102h and the feed port 102j of the molding apparatus 102 into the mold cavity 102i. In some embodiments, the flowable mixture 104 is supplied by a flowable mixture supply unit 103 connected to the ejector 101 a. In some embodiments, the flowable mixture 104 has a composition similar to that of the flowable mixture prepared by the supply unit 103 described above, and thus, for brevity, a duplicate description is omitted.

In some embodiments, during injection of the flowable mixture 104, the outlet 101c engages the opening 102h and contacts the step 102k, and the projection 101d of the first element 101b abuts the projection 102f of the second element 102 s. During injection of the flowable 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 ejection force I acts on the second element 102s and/or the forming device 102 to push the second element 102s and/or the forming device 102 away from the ejection unit 101 and thereby generate a reaction force C that is acted on the protrusion 101d by the protrusion 102f. During the injection of the flowable mixture 104, the protrusion 101d abuts the protrusion 102f. Thus, the engagement of the first member 101b and the second member 102s, and the engagement of the outlet 101c and the feed port 102j are ensured. This minimizes or even prevents the flowable mixture 104 from flowing out of the mold cavity 102i.

In operation 210, referring to fig. 14, after the flowable material 104 is ejected, the first element 101b is displaced toward the second element 102 s. In some embodiments, after the flowable material 104 is ejected, the protruding portion 101d of the first element 101b disengages from the protrusion 102f of the second element 102s while the protruding portion 101d of the first element 101b is received by the groove 102e of the second element 102 s.

In some embodiments, after the flowable mixture 104 is ejected, the first element 101b is displaced toward the second element 102s along arrow H as shown in fig. 14 until the first element 101b is disengaged from the second element 102 s. In some embodiments, the protrusion 101d moves away from the protrusion 102f. In some embodiments, the first element 101b moves toward the forming device 102 to disengage from the protrusion 102f. In some embodiments, the ejector 101a remains stationary as the first element 101b moves downward, as shown in fig. 14. In some embodiments, the first sensor 102l senses the separation of the protrusion 102f from the protruding portion 101d of the first element 101b.

In some embodiments, the third element 101g (not shown in fig. 14, shown in fig. 8) and the first element 101b are moved together in operation 210. In some embodiments, after the flowable material 104 is ejected, the protruding portion 101h (not shown in fig. 14, shown in fig. 8) of the third element 101g is displaced toward the second element 102 s. In some embodiments, the separation of the protrusion 101h of the third element 101g from the protrusion 102f of the second element 102s is sensed by the first sensor 102 l.

In operation 211, referring to fig. 15, the ejector 101a is displaced away from the molding device 102. In some embodiments, the outlet 101c is retracted from the forming device 102 after the flowable material 104 is ejected.

In some embodiments, after the first element 101b is disengaged from the second element 102s, the ejector 101a is moved away from the forming device 102 along arrow J as shown in fig. 15 until the outlet 101c of the ejector 101a does not contact the second element 102s. In some embodiments, the separation of the ejector 101a and the groove 102g is sensed by the second sensor 102 m. In some embodiments, the ejector 101a and the first element 101b move away from the forming device 102 along arrow J. In some embodiments, the ejector 101a and the first element 101b move together. In some embodiments, ejector 101a, first element 101b, and third element 101g move together.

In operation 212, referring to fig. 16 and 17, the second member 102s and the molding device 102 are displaced away from the injection unit 101 or the injection unit 101 is displaced away from the molding device 102.

In some embodiments, after the first element 101b and ejector 101a are disengaged from the second element 102s, the second element 102s and the molding device 102 are displaced away from the ejector unit 101. Alternatively, after the first element 101b and the ejector 101a are disengaged from the second element 102s, the ejector unit 101 is displaced away from the molding device 102. In some embodiments, the second element 102s and the forming device 102 move horizontally away from the first element 101b and the ejector 101a along arrow K, as shown in fig. 16. Alternatively, the first member 101b and the ejector 101a are horizontally moved away from the second member 102s and the molding device 102 along arrow M, as shown in fig. 16. Fig. 17 illustrates that after the second element 102s is displaced away from the ejection unit 101, the ejection unit 101 and the second element 102s are away from each other.

In operation 212, referring to fig. 18, the forming device 102 is displaced away from the second element 102s, or the second element 102s is displaced away from the forming device 102.

In some embodiments, after the forming device 102 is disengaged from the second element 102s, the forming device 102 is displaced away from the second element 102s. In some embodiments, the forming device 102 is displaced away from the second element 102s by rotating a carrier (not shown) held or disposed under the forming device 102. Alternatively, after the second member 102s is separated from the molding device 102, the injection unit 101, the molding device 102, and the second member 102s are separated from each other. In some embodiments, the forming device 102 moves horizontally away from the second element 102s. Alternatively, the second member 102s is moved horizontally away from the forming device 102. Fig. 18 illustrates the second element 102s and the forming device 102 being moved away from each other after the forming device 102 is moved away from the second element 102s.

Fig. 19 illustrates a schematic perspective view of a second injection molding system 300, according to one embodiment of the present invention. In some embodiments, referring to fig. 19, the second injection molding system 300 includes an injection unit 101, a molding device 102, and a support device 105 disposed between the injection unit 101 and the molding device 102. In some embodiments, the second injection molding system 300 further includes a flowable mixture supply unit 103 that can be in communication with the injection unit 101. In some embodiments, the flowable mixture supply unit 103 is configured to generate and supply a flowable mixture to the injection unit 101. In some embodiments, the flowable mixture includes a polymeric material, such as Ethylene Vinyl Acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic Polyurethane (TPU), thermoplastic polyester elastomer (TPEE), and the like. In some embodiments, the flowable mixture includes a recyclable material. In some embodiments, the flowable mixture further comprises a foaming agent.

In some embodiments, the flowable mixture supply unit 103 of the second injection molding system 300 includes an extruder (not shown) for converting the polymeric material into a molten state, and a mixer (not shown) for mixing the foaming agent into the polymeric material. The polymeric material may flow from the extruder into the mixer.

In some specific embodiments, the ejection unit 101 comprises several ejectors 101a arranged between the first element 101b and the third element 101g of the support device 105. In some embodiments, the support device 105 supports the ejector 101a. In some embodiments, each injector 101a is configured to receive the flowable mixture from the flowable mixture supply unit 103 and to discharge the flowable mixture from its outlet 101 c. In some embodiments, each injector 101a may be in communication with a mixer or flowable mixture supply unit 103. In some embodiments, the flowable mixture is discharged from the ejector 101a into the forming device 102. Each injector 101a may be engaged with a second element 102s of the support device 105. In some embodiments, the ejector 101a is fully engaged with the second element 102 s. In some embodiments, each ejector 101a may be vertically extended/retracted in a first direction as indicated by arrow a. In some embodiments, the ejectors 101a may be extended/retracted independently of each other. In some embodiments, each injector 101a may be extended/retracted by a hydraulic mechanism 101 e. In some embodiments, movement of each injector 101a is actuated and controlled by a hydraulic mechanism 101 e.

In some embodiments, the support device 105 is configured to facilitate engagement of the injection unit 101 and the molding device 102. In some embodiments, the support device 105 includes a first element 101b disposed proximate the ejector 101a, a third element 101g, and a second element 102s disposed on the molding device 102. In some embodiments, both the first element 101b and the third element 101g may be engaged with the second element 102s. The first element 101b and the third element 101g may extend toward the forming device 102 and retract from the forming device 102, respectively. In some embodiments, each of the first element 101B and the third element 101g can be vertically extended/retracted in a second direction as indicated by arrow B. In some embodiments, each of the first and third elements 101b, 101g may be extended/retracted along the track 101f by a motor (not shown) or the like. In some embodiments, each of the first and third elements 101b, 101g move along the track 101f, and the movement of each of the first and third elements 101b, 101g is actuated and controlled by one motor. In some embodiments, the first direction and the second direction are parallel.

In some embodiments, the ejector 101a, the first element 101b, and the third element 101g extend/retract independently of one another. The ejector 101a, the first element 101b and the third element 101g are displaceable relative to each other. In some embodiments, the ejector 101a, the first element 101b, and the third element 101g may be displaced separately or together. In some embodiments, all of the ejectors 101a move with each other, and the first and third elements 101b, 101g move with 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 protruding portion 101d that is engageable with the second element 102s, and the third element 101g includes a protruding portion 101h that is engageable with the second element 102 s.

In some embodiments, the injection unit 101 is disposed above the molding device 102. In some embodiments, the ejector 101a, the first element 101b, and the third element 101g are disposed above the molding apparatus 102. In some embodiments, the forming device 102 is configured to receive the flowable mixture exiting the injector 101a through the outlet 101 c.

In some embodiments, the molding apparatus 102 includes a first mold 102c and a second mold 102d engageable with the first mold 102 c. 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 may be engaged with the first mold 102 c. In some embodiments, the shaping device 102 is disposed on and movable with a carrier (not shown). In some embodiments, a plurality of molding devices 102 are arranged on the carrier, and the molding devices are arranged in a line, row, column, arc, curve, or any other suitable configuration. In some embodiments, the carrier is rotatable.

Fig. 20 illustrates a schematic perspective view of the second element 102s, and fig. 21 illustrates a schematic top view of the second element 102s. In some embodiments, referring to fig. 19-21, the support device 105 includes a second element 102s engageable with the first element 101b and the third element 101 g. In some embodiments, the second element 102s is disposed on the forming device 102. In some embodiments, the second element 102s includes a groove 102e defined by the protrusion 102f and a groove 102o defined by the protrusion 102 p.

In some embodiments, both the grooves 102e, 102o and the protrusions 102f, 102p are laterally elongated. The groove 102e is arranged to receive a protruding portion 101d of the first element 101b in the support means 105. The groove 102o is arranged to receive a protruding portion 101f of the third element 101g in the support means 105. In some embodiments, the protruding portion 101d of the first element 101b can slide within and along the groove 102e of the second element 102s, and the protruding portion 101f of the third element 101g can slide within and along the groove 102o of the second element 102s. In some embodiments, each of the length L1 of the groove 102e and the length L2 of the groove 102o is equal to the width W1 of the second element 102s. In some embodiments, the height H1 of the groove 102e of the second element 102s is greater than the thickness T1 of the protrusion 101d of the first element 101b, and the height H2 of the groove 102o of the second element 102s is greater than the thickness T2 of the protrusion 101H of the third element 101 g. In some embodiments, each of the protruding portion 101d of the first element 101b and the protruding portion 101h of the third element 101g is T-shaped and configured to be received in the groove 102e and the groove 102o, respectively.

In some embodiments, the molding device 102 includes a recess 102g configured to receive the outlet 101 e. In some embodiments, the groove 102g is disposed on the second element 102s and is elongated laterally along the second element 102s. In some embodiments, groove 102g is parallel to protrusions 102f and 102p. The groove 102g is provided to receive the outlet 101c of the ejector unit 101 or the end of the ejector 101 a. The outlet 101c or end of the ejector 101a is slidable within the groove 102g and along the groove 102g. In some embodiments, the opening 102h is disposed within the recess 102g. In some embodiments, the opening 102h extends through the second element 102s. The outlet 101c or end of the ejector 101a may be received by the opening 102 h. The outlet 101c or end of the ejector 101a is movable within the opening 102 h. In some embodiments, the width W3 of the opening 102h is substantially greater than the total width W2 of the outlet 101c of the ejector 101 a. In some embodiments, all of the outlets 101c of the ejector 101a are received by the opening 102 h.

In some embodiments, the first sensor 102l is disposed within the groove 102e and is configured to sense contact of the protrusion 101d with the groove 102e, and the third sensor 102q is disposed within the groove 102o and is configured to sense contact of the protrusion 101h with the groove 102 o. In some embodiments, the first sensor 102l is disposed at a middle end of the groove 102e and the third sensor 102q is disposed at a middle end of the groove 102 o. The first sensor 102l and the third sensor 102q are not limited to any particular type as long as they can sense pressure and provide pressure information.

In some embodiments, a plurality of first sensors 102l are disposed within the groove 102e, and the first sensors 102l are configured to sense the position and contact of the protrusion 101d with the groove 102 e. In some embodiments, the plurality of third sensors 102q are all disposed within the groove 102o, and the third sensors 102q are all configured to sense the position and contact of the protrusion 101h with the groove 102 o. The number and positions of the plurality of third sensors 102q are not particularly limited; for example, it may be disposed at any location of the protrusion 102p and within the groove 102 o; however, the present invention is not limited thereto.

In some embodiments, a step 102k is formed within the recess 102g and adjacent to the opening 102h. In some embodiments, the second sensor 102m is disposed within the groove 102g and is configured to sense contact of the outlet 101c and the groove 102 g.

In some embodiments, the second sensor 102m is disposed within the opening 102h. The second sensor 102m is not limited to any particular type as long as it can sense pressure and provide pressure information. In some embodiments, a plurality of second sensors 102m are disposed within the opening 102h, and the second sensors 102m are configured to sense the position and contact of the outlet 101c with the forming device 102. The number and positions of the plurality of second sensors 102m are not particularly limited; for example, it may be disposed anywhere in the opening 102 h; however, the present invention is not limited thereto.

In some embodiments, the forming device 102 may be in an open state and a closed state. The first mold 102c is engaged with the second mold 102d when the molding apparatus 102 is in the closed state. Fig. 22 illustrates a schematic perspective view of the molding apparatus 102 in a closed state, and fig. 23 illustrates a schematic cross-sectional view of the molding apparatus 102 in a 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 more than one mold cavity 102i. In some embodiments, the mold cavities 102i are isolated from each other. In some embodiments, the mold cavity 102i is configured to receive the flowable mixture from the injector 101a through the opening 102h and the feed port 102j of the second member 102 s. When the molding apparatus 102 is in the closed state, the mold cavity 102i is accessible only through the feed port 102j. When the molding apparatus 102 is in an open state, the mold cavity 102i may be accessed through a gap (not shown) between the first mold 102c and the second mold 102 d. In some embodiments, the molding apparatus 102 includes a feed port 102j that can be in communication with the mold cavity 102i. In some embodiments, the feed port 102j is disposed at the first die 102c and penetrates the first die 102c. In some embodiments, the forming device 102 includes a plurality of feed ports 102j, as shown in fig. 22 and 23. The feed ports 102j correspond to the mold cavities 102i, respectively. In some embodiments, when the second element 102s is disposed over the molding device 102, the opening 102h is aligned with the feed port 102j such that a flowable mixture can flow from the injector 101a into the mold cavity 102i through the opening 102h and the feed port 102j. In some embodiments, the openings 102h are disposed above all of the feed ports 102j. In some embodiments, the opening 102h overlaps the feed opening 102j when the second element 102s is disposed above the molding device 102 as viewed from a top view.

In the present invention, a second injection molding method 400 is also disclosed. The second injection molding method 400 includes many operations and the description and illustration is not to be considered as limiting the order of operations. Fig. 24 shows an embodiment of a second injection molding method 400. In some embodiments, the second injection molding method 400 includes a plurality of operations (401 through 413). Fig. 25-36 are schematic cross-sectional views of stages of the second injection molding method according to some embodiments of the invention. In some embodiments, the second injection molding method 400 is implemented by the second injection molding system 300 as shown in fig. 19-23 and discussed above.

In operation 401, referring to fig. 25, a second injection molding system 300 is provided that includes an injection unit 101, a molding apparatus 102, and a support apparatus 105. In some embodiments, the second injection molding system 300 includes the injection unit 101, the molding apparatus 102, and the support apparatus 105 as described above. The molding device 102 is in a closed state. The openings 102h of the second member 102s are aligned with the plurality of feed ports 102j of the molding apparatus 102 such that the mold cavity 102i is accessible through the openings 102h and the feed ports 102 j.

In operation 402, the protruding portion 101d of the first element 101b of the support device 105 is aligned with the first groove 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 groove 102e of the second element 102 s. In operation 404, the plurality of outlets 101c are aligned with the groove 102g of the second element 102s configured to receive the outlets 101 c. In some embodiments, the alignment of the protruding portion 101d of the first element 101b with the first groove 102e of the second element 102s, the alignment of the protruding portion 101h of the third element 101g with the second groove 102e of the second element 102s, and the alignment of the outlet 101c with the recess 102g are all performed simultaneously.

In some embodiments, ejector 101a is vertically displaced along arrow a so as to be horizontally aligned with groove 102g, and first element 101B and third element 101g are vertically displaced along arrow B so as to be horizontally aligned with first groove 102e and second groove 102e, respectively, as shown in fig. 25. In some embodiments, ejector 101a moves up or down to be horizontally aligned with recess 102 g. In some embodiments, the first and third elements 101b, 101g move up or down to be horizontally aligned with the first and second grooves 102e, respectively. Alternatively or simultaneously, the forming means 102 are displaced along arrow C and/or arrow D so as to be horizontally aligned with the protruding portion 101D of the first element 101b, the protruding portion 101h of the third element 101g and the outlet 101C or end of the ejector 101 a. In some embodiments, the molding device 102 is moved upward, downward, forward, and/or backward to horizontally align the first groove 102e with the projection 101d, horizontally align the second groove 102e with the projection 101h, and horizontally align the recess 102g with the outlet 101c or end of the injector 101 a.

In operation 405, referring to fig. 26 and 27, the ejection unit 101 is displaced to slide the protruding portion 101d of the first element 101b along the first groove 102e of the second element 102s and the protruding portion 101h of the third element 101g along the second groove 102e of the second element 102 s. In operation 406, the outlet 101c slides into the groove 102 g.

In some embodiments, after horizontal alignment, the second element 102s is moved toward the ejector unit 101 along arrow E, as shown in fig. 26. Alternatively, after the horizontal alignment, as shown in fig. 26, the ejection unit 101 is moved toward the second member 102s along an arrow L. Fig. 27 is a schematic cross-sectional view of the second injection molding system 300 of fig. 26. In some embodiments, the first element 101b slides along the first groove 102e, the third element 101g slides along the second groove 102e, and the outlet 101c or end of the ejector 101a slides along the groove 102 g. In some embodiments, the second element 102s is moved until the first element 101b is disposed within the first groove 102e, the third element 101g is disposed within the second groove 102e, and the outlet 101c or end of the ejector 101a is vertically aligned with the opening 102 h. As shown in fig. 27, the protrusion 102f is arranged opposite to the protrusion portion 101d of the first element 101b, and the protrusion 102p is arranged opposite to the protrusion portion 101h of the third element 101 g. The first element 101b, the third element 101g, and the ejector 101a are not in contact with the second element 102 s. In some embodiments, the outlets 101c of the ejectors 101a are each aligned with an opening 102 h. 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 outlet 101c and the top surface of the forming device 102.

In operation 407, the molding device 102 is displaced toward the injection unit 101 and the supporting device 105 to be disposed under the supporting device 105. In some embodiments, referring to fig. 28, after ejector 101a is aligned with opening 102h, ejector 101a and first element 101b are moved toward forming device 102 along arrow F, as shown in fig. 28. In some embodiments, the forming device 102 is moved until the support device 105 covers the forming device 102 and the ejector 101a is vertically aligned with the feed port 102j of the forming device 102. In some embodiments, the forming device 102 is moved by, for example, rotationally moving a carrier (not shown) disposed beneath the forming device 102. In some embodiments, the forming device 102 is moved until the outlet 101c or end of the ejector 101a is vertically aligned with the feed port 102j of the forming device 102.

In operation 408, referring to fig. 29, the outlet 101c is extended toward the forming device 102 to engage the outlet 101c with the forming device 102.

In some embodiments, after the ejector 101a is aligned with the opening 102h, as shown in fig. 28, the ejector 101a, the first element 101b, and the third element 101g are moved toward the molding apparatus 102 along arrow F until the outlet 101c of the ejector 101a contacts the second element 102s. In some embodiments, the outlet 101c is in contact with the first mold 102 c. In some embodiments, ejector 101a, first element 101b, and third element 101g move together. When the outlet 101c of the ejector 101a contacts the first mold 102c, the entire first element 101b and the entire third element 101g remain out of contact with the second element 102s, as shown in fig. 29. In some embodiments, contact of the forming device 102 and the outlet 101c is sensed by a second sensor 102m disposed within the recess 102 g. In some embodiments, contact of the shaping device 102 and the outlet 101c is continuously sensed.

In operation 409, referring to fig. 30, the first and third elements 101b and 101g are displaced away from the second element 102s while the first and third elements 101b and 101g are received by the second element 102 s. In some embodiments, the protruding portion 101d of the first element 101b is moved to abut against the protrusion 102f of the second element 102s while the protruding portion 101d of the first element 101b is received by the first groove 102e of the second element 102s and, when the protruding portion 101h of the third element 101g is received by the second groove 102e of the second element 102s, the protruding portion 101h of the third element 101g is moved to abut against the protrusion 102p of the second element 102 s.

In some embodiments, after the outlet 101c is in contact with the forming device 102, the first and third elements 101b, 101G are moved away from the second element 102s along arrow G, as shown in fig. 30, until the protruding portions 101d, 101h of the first and third elements 101b, 101G contact the protrusions 102f, 102p of the second element 102s, respectively. In some embodiments, the ejector 101a remains stationary as the first and third elements 101b, 101g move upward, as shown in fig. 30. As a result, both the first element 101b and the third element 101g are joined with the second element 102 s.

In some embodiments, the contact of the second element 102s and the first element 101b is sensed by the first sensor 102 l. In some embodiments, the first sensor 102l senses contact of the protrusion 102f with the protruding portion 101d of the first element 101 b. In some embodiments, the contact of the second element 102s and the first element 101b is sensed continuously. In some embodiments, contact of the second element 102s and the third element 101g is sensed by a third sensor 102q disposed on the protrusion 102p and within the second groove 102 e. In some embodiments, the contact of the second element 102s and the third element 101g is sensed by the third sensor 102 q. In some embodiments, the third sensor 102q senses contact of the protrusion 102p with the protruding portion 101h of the third element 101 g. In some embodiments, the contact of the second element 102s and the third element 101g is sensed continuously.

In operation 410, referring to fig. 31, the flowable mixture 104 is injected into the mold cavity 102i of the molding device 102.

In some embodiments, flowable mixture 104 is injected into mold cavity 102i after protrusion 101d contacts protrusion 102f and protrusion 101h contacts protrusion 102p, as shown in fig. 31. The flowable mixture 104 is discharged from the outlet 101c of the injector 101a into the mold cavity 102i through the opening 102h and the feed port 102 j. In some embodiments, the flowable mixture 104 is supplied by a flowable mixture supply unit 103 connected to the ejector 101 a. In some embodiments, the flowable mixture 104 has a composition similar to that of the flowable mixture prepared by the supply unit 103 described above, and thus, for brevity, a duplicate description is omitted.

In some embodiments, during the injection of the flowable mixture 104, the outlet 101c is engaged with the forming device 102, the protruding portion 101d of the first element 101b abuts the protrusion 102f of the second element 102s, and the protruding portion 101h of the third element 101g abuts the protrusion 102p of the fourth element 102 o. During injection of the flowable mixture 104 into the mold cavity 102I by the injector 101a, an injection force I is generated towards the molding apparatus 102. In some embodiments, the injection force I acts on the molding device 102 to push the molding device 102 away from the injection unit 101 and thereby generate a reaction force C that is acted on the projection 101d by the projection 102 f. During the injection of the flowable mixture 104, the protrusion 101d abuts the protrusion 102f and the protrusion 101h abuts the protrusion 102p. Thus, the engagement of the first member 101b and the second member 102s, the engagement of the third member 101g and the second member 102s, and the engagement of the outlet 101c and the feed port 102j are ensured. This minimizes or even prevents the flowable mixture 104 from flowing out of the mold cavity 102i.

In operation 411, referring to fig. 32, after the flowable material 104 is ejected, the first element 101b and the third element 101g are displaced toward the second element 102 s. In some embodiments, after the flowable material 104 is ejected, the protruding portion 101d of the first element 101b is disengaged from the protrusion 102f of the second element 102s and the protruding portion 101h of the third element 101g is disengaged from the protrusion 102p of the second element 102s, while the protruding portion 101d of the first element 101b is received by the first groove 102e of the second element 102s and the protruding portion 101h of the third element 101g is received by the second groove 102e of the second element 102 s.

In some embodiments, after the flowable mixture 104 is ejected, the first element 101b and the third element 101g are displaced toward the second element 102s along arrow H as shown in fig. 32 until the first element 101b is disengaged from the second element 102 s. In some embodiments, the protrusion 101d moves away from the protrusion 102f and the protrusion 101h moves away from the protrusion 102p. In some embodiments, the first element 101b moves toward the forming device 102 to disengage from the protrusion 102f, and the third element 101g moves toward the forming device 102 to disengage from the protrusion 102p. In some embodiments, the ejector 101a remains stationary as the first and third elements 101b, 101g move downward, as shown in fig. 32. In some embodiments, the separation of the protrusion 102f from the protrusion 101d of the first element 101b is sensed by the first sensor 102l and the separation of the protrusion 102p from the protrusion 101h of the third element 101g is sensed by the third sensor 102 q.

In operation 412, referring to fig. 33, the ejector 101a is displaced away from the molding apparatus 102. In some embodiments, the outlet 101c is retracted from the forming device 102 after the flowable material 104 is ejected.

In some embodiments, after the first and third elements 101b, 101g are disengaged from the second element 102s, the ejector 101a is moved away from the forming device 102 along arrow J as shown in fig. 33 until the outlet 101c of the ejector 101a does not contact the forming device 102. In some embodiments, the separation of the ejector 101a and the molding device 102 is sensed by the second sensor 102 m. In some embodiments, the ejector 101a, the first element 101b, and the third element 101g move away from the forming device 102 along arrow J. In some embodiments, ejector 101a, first element 101b, and third element 101g move together.

In operation 413, referring to fig. 34 and 35, the molding device 102 is displaced away from the injection unit 101, or the injection unit 101 is displaced away from the molding device 102.

In some embodiments, after the ejector 101a, the first element 101b, and the third element 101g are disengaged from the second element 102s, the molding device 102 is displaced away from the ejector unit 101. Alternatively, after the ejector 101a, the first element 101b, and the third element 101g are disengaged from the second element 102s, the ejector unit 101 is displaced away from the second element 102s. In some embodiments, the molding apparatus 102 is moved horizontally away from the ejector 101a, the first element 101b, and the third element 101g along arrow K, as shown in fig. 34. Alternatively, the ejector 101a, the first member 101b, and the third member 101g are horizontally moved away from the second member 102s and the molding device 102 along the arrow M, as shown in fig. 34. Fig. 35 illustrates that after the second element 102s is displaced away from the ejection unit 101, the ejection unit 101 and the second element 102s are away from each other.

In some embodiments, after the forming device 102 is disengaged from the second element 102s, the forming device 102 is displaced away from the second element 102s. In some embodiments, the forming device 102 is moved horizontally away from the second member 102s along arrow K, as shown in fig. 35. In some embodiments, the forming device 102 is displaced away from the second element 102s by rotating a carrier (not shown) disposed below the forming device 102, and another forming device (not shown) may be disposed below the second element 102s. Alternatively, after the second member 102s is separated from the molding device 102, the injection unit 101, the molding device 102, and the second member 102s are separated from each other. In some embodiments, the forming device 102 moves horizontally away from the second element 102s. Alternatively, the second member 102s is moved horizontally away from the forming device 102. Fig. 36 illustrates the second element 102s and the forming device 102 being moved away from each other after the forming device 102 is moved away from the second element 102s.

In the present invention, a third injection molding method 500 is also disclosed. The third injection molding method 500 includes many operations and the description and illustration is not to be considered as limiting the order of operations. Fig. 37 shows an embodiment of a third injection molding method 500. In some embodiments, the third injection molding method 500 includes a plurality of operations (501-506). In some embodiments, the third injection molding method 500 is implemented by the first injection molding system 100 as shown in fig. 1-5 or the second injection molding system 300 as shown in fig. 19-23 and discussed above.

In operation 501, an injection molding system is provided, wherein the injection molding system includes an injection unit including an outlet configured to discharge flowable material and a molding device configured to receive the flowable material from the outlet and including a mold cavity and a feed port communicable with and correspondingly engaged with the mold cavity.

In operation 502, a support device configured to facilitate engagement of the injection unit with the molding device is provided, wherein the support device includes a first element coupled to the injection unit and a second element disposed on the molding device.

In operation 503, the protruding portion of the first element is aligned with the groove of the second element.

In operation 504, the injection unit is displaced such that the protruding portion of the first element slides along the groove of the second element.

In operation 505, the outlet is displaced in the opening of the second element to engage the feed port when the protruding portion of the first element engages the groove of the second element.

In operation 506, the flowable material is injected into the mold cavity.

One aspect of the present invention relates to an injection molding system. The injection molding system includes: a supply unit configured to supply a flowable mixture of a polymeric material and a blowing agent; an injection unit communicable with the supply unit, wherein the injection unit includes an outlet disposed remote from the supply unit and configured to discharge the flowable mixture; a forming device configured to receive the flowable mixture from the outlet and comprising a mold cavity and a feed port communicable with the mold cavity and engaged with the outlet; and a support device disposed between the injection unit and the molding device and configured to facilitate engagement of the injection unit and the molding device. The support device comprises a first element connected to the injection unit and a second element arranged on the forming device. The second element includes a first groove configured to receive a protruding portion of the first element, the protruding portion of the first element being slidable within and along the first groove of the second element.

In some embodiments, the second element includes an opening configured to receive the outlet of the injection unit. In some embodiments, the second element further comprises a protrusion for defining a first channel, and both the first channel and the protrusion are laterally elongated. In some embodiments, the protruding portion of the first element is engageable with the protrusion and slidable within the groove. In some embodiments, the second member further comprises a groove configured to receive the outlet, and the groove extends laterally along the second member and parallel to the first groove. In some embodiments, the outlet is slidable within and along the groove. In some embodiments, the second member further comprises an opening disposed within the recess. In some embodiments, a first sensor is disposed within the first channel and is configured to sense contact of the protruding portion with the first channel. In some embodiments, a second sensor is disposed within the recess and is configured to sense contact of the outlet with the recess. In some embodiments, the height of the first groove is greater than the thickness of the protruding portion of the first element. In some embodiments, the support device further comprises a third element connected to the injection unit, and the first groove is configured to receive the first element and the third element. In some embodiments, the support device further comprises a third element connected to the injection unit, and the second element further comprises a second groove configured to receive the third element.

One aspect of the present invention relates to an injection molding method. The molding method comprises the following steps: providing an injection molding system, wherein the injection molding system comprises an injection unit and a molding device, the injection unit comprising an outlet configured to discharge flowable material, and the molding device being configured to receive the flowable material from the outlet and comprising a mold cavity and a feed port communicable with and correspondingly engaged with the mold cavity; providing a support device configured to facilitate engagement of the injection unit with the molding device, wherein the support device comprises a first element connected to the injection unit and a second element disposed on the molding device; aligning the protruding portion of the first element with the groove of the second element; displacing the injection unit to slide the protruding portion of the first element along the groove of the second element; when the protruding portion of the first element is engaged with the groove of the second element, the outlet is displaced in an opening of the second element such that the outlet is engaged with the feed port; and injecting the flowable material into the mold cavity.

In some embodiments, the method further comprises aligning the outlet with a groove configured to receive the outlet, the groove extending laterally along the second member and parallel to the groove; and sliding the outlet into the recess. In some embodiments, the alignment of the protruding portion of the first element with the groove of the second element and the alignment of the outlet with the groove are performed simultaneously. In some embodiments, the method further comprises extending the outlet toward the forming device such that the outlet engages the feed inlet; and retracting the outlet away from the forming device after the flowable material is ejected. In some embodiments, the method further comprises: moving the protruding portion of the first element to abut against a protrusion of the second element while the protruding portion of the first element is received by the groove of the second element; and disengaging the protruding portion of the first element from the groove of the second element after the flowable material is ejected, wherein the groove is defined by the protrusion. In some embodiments, the first element moves away from the forming device to abut the protrusion and moves toward the forming device to disengage from the protrusion. In some embodiments, the method further comprises: after the flowable material is ejected, moving the protruding portion of the first element toward the forming device while the protruding portion of the first element is received by the groove of the second element; wherein the injection unit remains stationary while the support device moves towards the forming device. In some embodiments, the protruding portion of the first element abuts a protrusion of the second element during ejection of the flowable material, and the outlet is in communication with the feed port.

The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the various aspects of the invention. Those skilled in the art should appreciate that they can readily use the present invention as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.

Furthermore, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. It will be readily apparent to those skilled in the art from this disclosure that programs, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Symbol description

100 first injection molding system

101 injection unit

101a ejector

101b first element

101c outlet

101d,101h, protruding portion

101e hydraulic mechanism

101f track

101g third element

102 molding device

102c first die

102d second die

102e groove

102o, grooves; fourth element

102f,102p, protrusion

102g groove

102h opening

102i cavity of mold

102j feed inlet

102k step

102l first sensor

102m second sensor

102s second element

102x first part

102y second part

103 a flowable mixture supply unit; supply unit

104, a flowable mixture; flowable material

105 supporting device

200 first injection molding method

201-212,401-413,501-506 operation

300 second injection molding system

400 second injection molding method

500 third injection molding method

Reaction force C

D1 first distance

D2 second distance

D3, D4 distance

H1, H2 height

I injection force

L1, L2 length

T1, T2 thickness

W1, W2, W3, W4: width.

Claims

1. An injection molding system, comprising:

a supply unit configured to supply a flowable mixture of a polymeric material and a blowing agent;

an injection unit communicable with the supply unit, wherein the injection unit includes an outlet disposed remote from the supply unit and configured to discharge the flowable mixture;

A forming device configured to receive the flowable mixture from the outlet and comprising:

a mold cavity; and

a feed port in communication with the mold cavity and engageable with the outlet; and

a support means arranged between the injection unit and the forming means and arranged to facilitate engagement of the injection unit and the forming means,

wherein the support device comprises a first element connected to the injection unit, and a second element arranged on the forming device, the second element comprising a first groove arranged to receive a protruding portion of the first element, the protruding portion of the first element being slidable within and along the first groove of the second element.

2. The injection molding system of claim 1, wherein the second member comprises an opening configured to receive an outlet of the injection unit.

3. The injection molding system of claim 1, wherein the second member further comprises a groove configured to receive the outlet, and wherein the groove extends laterally along the second member and parallel to the first groove.

4. The injection molding system of claim 3, wherein the outlet is slidable within and along the recess.

5. The injection molding system of claim 3, wherein the second member further comprises an opening disposed within the recess.

6. The injection molding system of claim 1, wherein the support device further comprises a third member coupled to the injection unit, and the first channel is configured to receive the first member and the third member.

7. The injection molding system of claim 1, wherein the support device further comprises a third member coupled to the injection unit, and the second member further comprises a second channel configured to receive the third member.

8. An injection molding method, comprising:

providing an injection molding system, wherein the injection molding system comprises an injection unit and a molding device, the injection unit comprising an outlet configured to discharge flowable material, and the molding device being configured to receive the flowable material from the outlet and comprising a mold cavity and a feed port communicable with and correspondingly engaged with the mold cavity;

providing a support device configured to facilitate engagement of the injection unit with the molding device, wherein the support device comprises a first element connected to the injection unit and a second element disposed on the molding device;

Aligning the protruding portion of the first element with the groove of the second element;

displacing the injection unit to slide the protruding portion of the first element along the groove of the second element;

when the protruding portion of the first element is engaged with the groove of the second element, the outlet is displaced in an opening of the second element such that the outlet is engaged with the feed port; and

injecting the flowable material into the mold cavity.

9. The method of claim 8, further comprising:

aligning the outlet with a recess arranged to receive the outlet, the recess extending laterally along the second member and parallel to the channel; and

the outlet is slid into the recess.

10. The method of claim 8, further comprising:

moving the protruding portion of the first element to abut against a protrusion of the second element while the protruding portion of the first element is received by the groove of the second element; and

after the flowable material is ejected, the protruding portion of the first element is disengaged from the groove of the second element,

wherein the groove is defined by the protrusion.