TWM637387U - Composite and molding device of manufacturing the same - Google Patents

Abstract

A composite includes a flexible layer and a molding material in contact with at least a portion of the flexible layer. a molding device of manufacturing the composite, comprising: a first mold; a second mold complementary with the first mold; and a mold cavity defined by the first mold and the second mold, the mold cavity includes a first mold cavity defined by the first mold and a second mold cavity defined by the second mold; wherein an inner wall of the first mold cavity is configured to make at least a portion of the the flexible layer to be pushed or pulled toward the inner wall, and the mold cavity is configured to inject a molding material therein, and cause the molding material in contact with the at least a portion of the flexible layer in the mold cavity to form the composite.

Description

Compound and molding device for preparing compound

The present invention relates to a composite and a molding device for preparing the composite, in particular to a composite containing molding materials and prepared in the molding device.

Molding materials containing polymers have many advantages such as high strength, low weight, impact resistance, heat insulation, and the like. Articles of such molding materials can be produced by injection molding or molding. For example, after a polymer is melted and mixed with a foaming agent to form a molding material, force or pressure is applied to the molding material to inject or extrude the mixture into a cavity of a mold and allow the mixture to foam in the cavity. Foam and cool to form the foam structure. In order to make the foamed structure have more uses, the foamed structure can be combined with other parts to form a composite, which can be applied in various fields.

One object of the present disclosure is to provide a complex.

According to a specific embodiment of the present disclosure, a complex is disclosed. The composite includes a flexible layer and a molding material in contact with at least a portion of the flexible layer.

According to a specific embodiment of the present invention, a method for preparing molding materials containing A molding device for a compound of a material and a flexible layer. The molding device includes a first mold base, a second mold base, which can be matched with the first mold base; and a molding cavity defined by the first mold base and the second mold base, the molding cavity Including a first mold cavity defined by the first mold base and a second mold cavity defined by the second mold base; wherein an inner wall of the first mold cavity is used to make at least a part of the flexible layer Pushed or pulled toward the inner wall, the molding cavity is used to inject the molding material, and the at least a portion of the flexible layer contacts the molding material in the molding cavity and forms the composite.

10:Extrusion system

20a, 20b: complex

21: Foam structure

22: flexible layer

30: Forming device

31: Cavity

32: Second mold base

33: The first mold base

34: Upper mold seat

35: feed port

36:Pressure regulation system

40: support device

41: First component

42:Second component

50: discharge channel

51: Outlet

60: Control system

61: CPU

62: Sensor

63: cable

100: Injection molding system

120: melting unit

121: pressurized box

122: The first feed channel

123: The first discharge channel

124: push components

125: Feed hopper

130: Hybrid unit

131:Hollow mixing box

132: the second feed channel

133: Second discharge channel

134: mixing rotor

140: Blowing agent supply unit

150: Injection unit

151: Hollow metering box

152: Connection channel

153: discharge components

154: export

161: first flow control element

162: second flow control element

171: The first interface

172: Second interface

180:Monitoring module

181: CPU

182: sensor

210: texture

211: first surface

212: second surface

321: Second cavity

331: The first cavity

332: inner wall

341: opening

361: First gas conduit

362: Second gas conduit

363: gas source

364: first valve

365: second valve

366: Pressure sensing unit

371,372: connection points

411: slender part

412: arm

910,920: method

911, 912, 913, 921, 922, 923, 924, 925: steps

1211: interior space

1212: inner wall

1311: inner wall

1341: Cylindrical column

1342: Groove part

1511: interior space

D1, D3: the shortest distance

D2, D4: diameter

G: gas

M: molding material

P,P1,P2,P3: position

The present inventive aspects are best understood from the following detailed description when read with the accompanying drawings. It should be noted that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of many of the features may be arbitrarily expanded or reduced for clarity.

FIG. 1 is a schematic diagram of a compound according to a specific embodiment of the present invention.

FIG. 2 is a schematic diagram of a compound according to an embodiment of the present invention.

FIG. 3 is a flowchart illustrating a method for preparing a composite according to a specific embodiment of the present invention.

FIG. 4 is a flowchart illustrating a method for preparing a composite comprising a molding material and a flexible layer according to an embodiment of the present invention.

5 to 11 are schematic diagrams illustrating exemplary operations of a method for preparing a composite according to a specific embodiment of the present invention.

12 and 13 are schematic diagrams of an injection molding system according to a specific embodiment of the present invention.

14 is a schematic diagram of a portion of the injection molding system of FIGS. 12 and 13 according to an embodiment of the present invention.

Fig. 15 is a dotted line in Fig. 12 and Fig. 13 according to a specific embodiment of the present invention. Enlarged view of a portion of the injection molding system circled.

16 is a graph illustrating the relationship between the amount of foaming agent and the shortest distance in a mixture according to an embodiment of the present invention.

17 is a graph illustrating the behavior of the ratio of blowing agent to polymer material versus the ratio of shortest distance to mixing rotor diameter, according to an embodiment of the present invention.

18 and 19 are schematic diagrams of a portion of an injection molding system according to an embodiment of the present invention.

Figure 20 is a top view of a composite according to an embodiment of the present invention.

Figure 21 is a top view of a composite according to an embodiment of the present invention.

Figure 22 is a top view of a composite according to an embodiment of the present invention.

[Cross Reference to Related Applications]

This application claims U.S. Provisional Application No. 63/236,051 filed on August 23, 2021, U.S. Provisional Application No. 63/236,044 filed on Aug. 23, 2021, and U.S. Provisional Application No. 17/582,798 filed on Jan. 24, 2022 The priority of the US patent application is hereby incorporated by reference in its entirety.

The following description provides many different specific embodiments, or examples, for implementing different features of the presented subject matter. Concrete examples of components and configurations are described below to simplify this authoring. Of course, these are merely examples, not limitations. For example, the following description of forming a first feature on or over a second feature may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which a feature may be formed between the first and second features. Additional features such that the first and second features are not in direct contact with specific embodiments. Additionally, this creation may repeat reference numbers and/or letters in various instances. The purpose of this repetition is for simplicity and clarity and does not in itself indicate the Relationships between various specific embodiments and/or configurations discussed.

In addition, spatial relative terms such as "under", "under", "under", "above", "above", etc. may be used herein to facilitate describing the relationship of one element or feature to another element or feature, such as shown in the figure. Such spatially relative terms 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 terms used herein interpreted accordingly.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in 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. Additionally, as used herein, the term "about" generally means within 10%, 5%, 1%, or 0.5% of a known value or range. Alternatively, when considered by the skilled artisan, the term "about" means within an acceptable standard error of the mean. Except in operating/working examples, or unless expressly stated otherwise, all numerical ranges, amounts, values and percentages stated herein, such as amounts of material, durations, temperatures, operating conditions, ratios of quantities, etc., are to be understood as In all cases it is modified by the term "substantially", "approximately" or "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in this creation and appended claims are approximations that may vary as desired. At a minimum, each numerical parameter should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Herein, ranges may be expressed as from one endpoint to another or between two endpoints. All ranges disclosed herein are inclusive of endpoints unless otherwise stated.

FIG. 1 is a schematic diagram of a composite according to a specific embodiment of the present invention. The composite 20a includes a foamed structure 21 and a flexible layer 22 . In some embodiments, foam structure 21 is disposed on flexible layer 22 . In some embodiments, the flexible layer 22 wraps the hair Bubble structure21. In some embodiments, foamed structure 21 is in contact with flexible layer 22 . In some embodiments, foamed structure 21 conforms to flexible layer 22 . In some embodiments, a portion of the foamed structure 21 is exposed from the flexible layer 22 . In some embodiments, flexible layer 22 covers foam structure 21 . In some embodiments, the composite 20 a has a first surface 211 and a second surface 212 opposite to the first surface 211 , the second surface 212 is in contact with the flexible layer 22 . In some embodiments, flexible layer 22 is a layer. In some embodiments, the flexible layer 22 has a third surface, and at least a part of the third surface is overlapped and connected with the foam structure 21 . In some embodiments, at least a portion of the third surface of the flexible layer 22 is in contact with the second surface 212 of the composite 20a.

In some embodiments, foamed structure 21 includes a molding material. In some embodiments, foamed structure 21 is formed from a molding material. In some embodiments, the molding material includes a polymer material and a blowing agent. In some embodiments, the polymeric material includes ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), and the like. In some embodiments, the polymeric material includes a foamable material.

In some embodiments, the blowing agent includes a physical or chemical additive that releases gas and thereby forms bubbles. In some embodiments, the blowing agent includes any type of physical blowing agent known to those of ordinary skill in the art. In some embodiments, the blowing agent includes a supercritical fluid. Supercritical fluids may include inert gases such as carbon dioxide or nitrogen, hydrocarbons, chlorofluorocarbons, or mixtures thereof. The technical details of mixing the polymeric material and the foaming agent are prior art, and will not be repeated here. The blowing agent can be supplied in any flowable physical state, such as gas, liquid or supercritical fluid (SCF). In some embodiments, the blowing agent is in a supercritical state.

In some embodiments, foamed structure 21 has a density equal to or less than 0.4 g/cm ³ . In some embodiments, when the blowing agent includes a physical blowing agent, the foamed structure 21 of the present invention may have a density equal to or less than 0.4 g/cm ³ . In some embodiments, when the blowing agent includes a physical blowing agent, the density of the foamed structure 21 of the present invention may be between 0.1 g/cm ³ and 0.4 g/cm ³ .

In some embodiments, foamed structure 21 has a density equal to or less than 0.4 g/cm ³ . In some embodiments, when the blowing agent includes a physical blowing agent, the foamed structure 21 may have a density equal to or less than 0.4 g/cm ³ . In some embodiments, when the blowing agent includes a physical blowing agent, the foamed structure 21 of the present invention may be between 0.1 g/cm ³ and 0.4 g/cm ³ .

In some embodiments, flexible layer 22 is uniform in thickness. In some embodiments, flexible layer 22 includes a polymer material. The polymeric material of the flexible layer 22 may be similar or different from the polymeric material of the molding material. In some embodiments, the flexible layer 22 may be replaced by a non-flexible layer (not shown) including cloth material, leather material, polymer material, or the like.

FIG. 2 is a schematic diagram of a composite according to an embodiment of the present invention. In some embodiments, the present invention provides a composite 20b as shown in FIG. 2 . In some embodiments, referring to FIG. 2 , composite 20 b includes curved surface 23 . In some embodiments, flexible layer 22 is curved and forms curved surface 23 , and foamed structure 21 conforms to flexible layer 22 . In some embodiments, the composite 20 b has a first surface 211 and a second surface 212 opposite to the first surface 211 , and the second surface 212 is in contact with the flexible layer 22 . The curved surface 23 is conformal to the second surface 212 .

The present work discloses a method of preparing the complex. The method includes many operations, and the description and illustration are not to be considered as limitations on the order of operations. FIG. 3 is a flowchart illustrating a method for preparing a composite according to a specific embodiment of the present invention. In some embodiments, the method for preparing the composite 20a and the composite 20b can be formed by the method shown in FIG. 3 . In some embodiments, please refer to FIG. 3 , the method 910 of preparing the compound 20a, the compound 20b includes the following steps.

Step 911 includes placing a flexible layer between a first mold base and a second mold base wherein at least a portion of the flexible layer is located in a molding cavity defined by the first mold base and the second mold base, the molding cavity includes a first mold cavity of the first mold base and the second mold base A second mold cavity of the second mold base.

Step 912 includes pushing or pulling the at least a portion of the flexible layer toward the first mold holder, placing the at least a portion of the flexible layer in the first mold cavity.

Step 913 includes injecting a molding material into the molding cavity, bringing the molding material into contact with the at least a portion of the flexible layer disposed in the first cavity and forming the composite.

The present work discloses a method of preparing a composite comprising a molding material and a flexible layer. The method includes many operations, and the description and illustration are not to be considered as limitations on the order of operations. FIG. 4 is a flowchart illustrating a method for preparing a composite comprising a molding material and a flexible layer according to an embodiment of the present invention. In some embodiments, the method for preparing the composite 20a and the composite 20b can be formed by the method shown in FIG. 4 . In some embodiments, please refer to FIG. 4 , the method 920 of preparing the compound 20a, the compound 20b includes the following steps.

Step 921 includes providing a molding device, the molding device includes a first mold base and a second mold base that can be matched with the first mold base, and a mold base defined by the first mold base and the second mold base The molding cavity includes a first cavity of the first mold base and a second cavity of the second mold base.

Step 922 includes placing a flexible layer between the first mold base and the second mold base.

Step 923 includes aligning the first mold base and the second mold base so that at least a portion of the flexible layer is located in the molding cavity.

Step 924 includes injecting or expelling a gas into or out of the molding cavity such that at least one A portion of the flexible layer is pushed or pulled toward an inner wall of the first mold base by the gas.

Step 925 includes injecting a molding material into the molding cavity, bringing the molding material into contact with the flexible layer and forming the composite, wherein at least a portion of the flexible layer is located between the molding material and the first mold base , and the molding material contains foam material.

5 to 12 are schematic diagrams illustrating exemplary operations of a method for preparing a composite according to a specific embodiment of the present invention. 5 to 12 take the preparation of the compound 20b as an example, but the invention is not limited thereto. In some embodiments, please refer to FIG. 5, the method 920 includes step 921, which step provides a molding device 30, the molding device 30 includes a first mold base 33 and a second mold base 32 that can be mated with the first mold base 33, And the mold cavity 31 defined by the first mold base 33 and the second mold base 32 , the mold cavity 31 includes the first mold cavity 331 of the first mold base 33 and the second mold cavity 321 of the second mold base 32 .

In some embodiments, please refer to FIG. 5 , the forming device 30 includes an upper mold seat 34 and a mold located below the upper mold seat 34 . In some embodiments, the mold includes a second mold base 32 located below the upper mold base 34 and a first mold base 33 opposite to the second mold base 32 . The mold cavity 31 may be defined by the second mold cavity 321 of the second mold base 32 and the first mold cavity 331 of the first mold base 33 . In some embodiments, the second mold base 32 is an upper mold base, and the first mold base 33 is a lower mold base.

In some embodiments, the second mold base 32 and the first mold base 33 are separated from each other. In some embodiments, the second mold base 32 and the first mold base 33 can be mated and complementary to each other and can be separated. In some embodiments, when the second mold base 32 and the first mold base 33 are mated and complementary, the mold cavity 31 is defined. In some embodiments, the inner sidewall 332 of the first mold base 33 is curved. In some embodiments, the inner wall 332 of the first mold base 33 is a concave curved surface, a convex curved surface, or a curved surface including a combination of concave and convex surfaces.

In some embodiments, at least one feed port 35 is provided on the molding device 30 superior. In some embodiments, the feed inlet 35 is disposed above the second mold base 32 or the first mold base 33 and communicates with the mold cavity 31 , the second mold base 32 , the second mold cavity 321 or the first mold cavity 331 . For clarity and simplicity, Figure 5 shows one die with two feed ports 35, but such an example is illustrative only and not limiting of the embodiments. Those skilled in the art can easily understand that a mold can include one or more feed ports 35 communicating with the first cavity 331 or the second cavity 321 .

The feed port 35 is used to receive molding material into the mold cavity 31 . In some embodiments, the forming device 30 is provided with a plurality of feeding ports 35 . The molding material can be delivered into the molding device 30 through the feed opening 35 . In some embodiments, feed ports 35 may have different widths or diameters. In some embodiments, the molding material M is injected into the mold cavity 31 , and then the foamed structure 21 is formed in the mold cavity 31 after a period of time (as shown in FIG. 10 ).

In some embodiments, upper mold seat 34 includes opening 341 . Each opening 341 extends through the upper mold holder 34 . The upper mold base 34 may be mounted on the second mold base 32 by screws, clamps, fastening means or the like. In some embodiments, the upper mold base 34 is made of the same material as the second mold base 32 . In some embodiments, the width of the upper mold base 34 is greater than the width of the second mold base 32 or the first mold base 33 .

In some embodiments, forming apparatus 30 also includes one or more pressure regulation systems 36 . In some embodiments, inner sidewall 332 defines first cavity 331 , and connection point 372 connects with first cavity 331 . In some embodiments, the connection point 371 is connected to the second cavity 321 . In some embodiments, connection points 371 , 372 are configured to allow fluid or gas to enter or exit forming device 30 . The position, shape and quantity of the connection points 371 and 372 are not particularly limited, and can be adjusted as required. In some embodiments, connection points 371, 372 are holes, respectively.

The pressure regulating system 36 may include a first gas conduit 361, a second gas conduit Tube 362 , gas source 363 , first valve 364 , second valve 365 and pressure sensing unit 366 . The first gas conduit 361 is coupled to a connection point 371 and the other end of the first gas conduit 361 is coupled to a gas source 363 . In some embodiments, the gas source 363 is configured to supply a fluid or gas, wherein a suitable fluid or gas may be provided as needed; for example, the fluid or gas may be air, an inert gas, etc., but the invention is not limited thereto. In some embodiments, one end of first gas conduit 361 is coupled to connection point 372 .

In some embodiments, connection points 371, 372 are configured to supply gas or exhaust gas. The first valve 364 is disposed at the first gas conduit 361 and is used to control whether the gas from the gas source 363 enters the mold cavity 31 through the first gas conduit 361 and the connection point 371 . In some embodiments, when the first valve 364 is open and the second valve 365 is closed, fluid or gas is supplied to the cavity 31; when the first valve 364 is closed and the second valve 365 is open, at least a portion of the cavity 31 Fluid or gas is expelled.

In some embodiments, second gas conduit 362 is connected to connection point 372 . The second valve 365 is disposed at the second gas conduit 362 and is configured to control whether the gas from the mold cavity 31 is exhausted through the connection point 372 and the second gas conduit 362 . In some embodiments, second gas conduit 362 is coupled to connection point 371 .

In some embodiments, one end of the second gas conduit 362 is connected to the mold cavity 31, and the other end communicates with a space whose pressure is lower than the pressure in the mold cavity 31; for example, an external environment or a negative pressure space; however, the invention is not limited thereto . In some embodiments, the first valve 364 and the second valve 365 are not open at the same time.

The pressure sensing unit 366 is used to sense the pressure in the mold cavity 31 . The pressure sensing unit 366 is not limited to any particular type as long as it can sense pressure and provide pressure information after sensing the pressure inside the cavity 31 . The pressure regulating system 36 changes the gas flow in real time according to the pressure information. The condition of the mold cavity 31 can be adjusted, thereby adjusting the pressure in the mold cavity 31, so that the manufactured composite 20a, 20b has the required predetermined shape and performance.

In some embodiments, the pressure sensing unit 366 is disposed in the mold cavity 31 , the first gas conduit 361 or the second gas conduit 362 . In some embodiments, the pressure sensing unit 366 is disposed in the mold cavity 31 and away from the feeding port 35 . In some embodiments, pressure regulation system 36 has a plurality of pressure sensing units 366 . The number and location of the plurality of pressure sensing units 366 are not particularly limited, for example, they may be arranged on the inner sidewall of the mold cavity 31 and spaced apart from each other, and/or anywhere in the first gas conduit 361, and/or at the second Anywhere in the second gas conduit 362; however, the invention is not limited thereto.

In some embodiments, the method 920 includes a step 922 , please refer to FIG. 6 , the step 922 includes placing the flexible layer 22 between the first mold base 33 and the second mold base 32 . In some embodiments, the flexible layer 22 is disposed on the first mold cavity 331 of the first mold base 33 . In some embodiments, when the flexible layer 22 is disposed in the first mold cavity 331 of the first mold base 33 , the flexible layer 22 is connected to the first mold base 33 by at least one positioning unit (not shown) of the first mold base 33 . align. In some embodiments, at step 922 , the first mold base 33 is separated from the second mold base 32 . In some embodiments, the portion of the flexible layer 22 overlapping the first mold cavity 331 is not in contact with the first mold base 33 in a top view. In some embodiments, the flexible layer 22 is in contact with and supported by the outer periphery of the first die holder 33 . In some embodiments, a portion of the flexible layer 22 is disposed outside the first mold base 33 , and the portion of the flexible layer 22 disposed outside the first mold base 33 does not overlap the first mold base 33 in a plan view.

In some embodiments, the flexible layer 22 may be softened to enhance its flexibility prior to forming the composites 20a, 20b. For example, to enhance flexibility, the flexible layer 22 may be heated by infrared light at about 120° C. for 40 seconds to 45 seconds. As another example, the flexible layer can be irradiated with ultraviolet light 22 to enhance flexibility. After the flexibility is enhanced, the flexible layer 22 is more likely to conform to the inner sidewall 332 of the first mold base 33 during the molding process. At step 922 , the flexible layer 22 has not yet conformed to the inner sidewall 332 , and part of the flexible layer 22 has not yet contacted the inner sidewall 332 .

In some embodiments, after the flexible layer 22 can be softened by a heater to enhance flexibility, the flexible layer 22 is disposed on the first mold cavity 331 of the first mold base 33 . In some embodiments, after the flexible layer 22 is disposed on the first mold cavity 331 of the first mold base 33 , the flexible layer 22 is softened by a heater to enhance flexibility. In some embodiments, the flexible layer 22 with enhanced flexibility is disposed on the first mold cavity 331 of the first mold base 33 .

In some embodiments, method 910 includes step 911, please refer to FIG. 5 and FIG. The layer 22 is located in the mold cavity 31 defined by the first mold base 33 and the second mold base 32, and the mold cavity 31 includes the first mold cavity 331 of the first mold base 33 and the second mold cavity 321 of the second mold base 32 .

In some embodiments, the method 920 includes a step 923 , please refer to FIG. 7 , the step 923 includes fitting the first mold base 33 and the second mold base 32 so that at least a part of the flexible layer 22 is located in the mold cavity 31 . In some embodiments, the second mold base 32 is disposed above the first mold base 33 to define the molding cavity 31 by the second mold cavity 321 of the second mold base 32 and the first mold cavity 331 of the first mold base 33 . In some embodiments, the second mold cavity 321 is disposed between the flexible layer 22 and the second mold base 32 . The flexible layer 22 is disposed within the mold cavity 31 and between the second mold cavity 321 and the first mold cavity 331 . In some embodiments, the position of the flexible layer 22 is fixed between the first mold base 33 and the second mold base 32 by clamping the second mold base 32 and the first mold base 33 . In some embodiments, in step 923, the flexible layer 22 is simultaneously in contact with the peripheral edge of the first mold base 33 and the peripheral edge of the second mold base 32, and the flexible layer 22 is clamped between the first mold base 33 and the second mold base 32. between. In some embodiments, clamped The flexible layer 22 between the first mold base 33 and the second mold base 32 can move slightly.

In some embodiments, method 910 includes step 912, please refer to FIG. in the first cavity 331. In some embodiments, the method 920 includes a step 924, which includes injecting gas G into or exhausting the mold cavity 31, so that at least a portion of the flexible layer 22 is pushed or pulled toward the inner wall of the first mold base 33 by the gas G 332.

In some embodiments, a portion of the flexible layer 22 within the mold cavity 31 conforms to the inner sidewall 332 of the first mold base 33 . In some embodiments, the gas G is injected into the mold cavity 31 from the second mold base 32 and/or the gas G is extracted from the mold cavity 31 through the first mold base 33 to attach a part of the flexible layer 22 to the first mold base 33. On the inner side wall 332 of a mold base 33 . In some embodiments, portions of flexible layer 22 located within mold cavity 31 are stretched. In some embodiments, the flexible layer 22 covers the inner sidewall 332 of the first mold base 33 . In some embodiments, another portion of the flexible layer 22 is disposed between the second mold base 32 and the first mold base 33 . In some embodiments, in order for the flexible layer 22 to conform to the inner sidewall 332 of the first mold base 33, the position of the flexible layer 22 may shift slightly when the flexible layer 22 is in contact with the second mold base 32 and the first mold base 33 .

In some embodiments, gas G is injected into the mold cavity 31 through the first gas conduit 361 , and the gas G pushes the flexible layer 22 toward the inner sidewall 332 of the first mold base 33 . In some embodiments, gas G is injected into the mold cavity 31 through the first gas conduit 361 , and the gas G pushes the flexible layer 22 until the flexible layer 22 touches the inner sidewall 332 of the first mold base 33 . In some embodiments, when the gas G is injected, the first valve 364 is open. In some embodiments, when the gas G is injected, the second valve 365 is closed.

In some embodiments, the gas G in the first mold cavity 331 of the first mold base 33 is exhausted from the mold cavity 31 through the second gas conduit 362, so that the gas G pulls the flexible layer 22 toward the first mold base 33 The inner side wall 332 of. In some embodiments, the gas G is exhausted from the mold cavity 31 through the second gas conduit 362 . In some embodiments, the second valve 365 opens when the gas G is exhausted. In some embodiments, the first valve 364 opens when the gas G is exhausted.

In some embodiments, the gas G is injected into the mold cavity 31 through the first gas conduit 361 and simultaneously discharged from the mold cavity 31 through the second gas conduit 362 , so that the flexible layer 22 moves toward the inner sidewall 332 of the first mold base 33 .

In some embodiments, method 910 includes step 913, please refer to FIG. 9 and FIG. Portions of the flexible layer 22 contact and form the composite 20a. In some embodiments, method 920 includes step 925, step 925 includes injecting molding material M into mold cavity 31, making molding material M contact flexible layer 22 and forming composite 20b, wherein at least a portion of flexible layer 22 is located Between the molding material M and the first mold base 33 , the molding material M includes a foam material. In some embodiments, the molding material M includes a foaming agent.

In some embodiments, please refer to FIG. 9 , before step 913 or step 925, the method 910 and the method 920 further include making the mold cavity 31 have a first A predetermined pressure. In some embodiments, the gas G is injected into the mold cavity 31 through the pressure regulating system 36 connected to the mold cavity 31 until the mold cavity 31 is sensed to have a first A predetermined pressure. In some embodiments, the gas G is injected into the mold cavity 31 through the first gas conduit 361 . In some embodiments, gas G is any suitable gas, depending on the needs; for example, air; however, the invention is not limited thereto. In some embodiments, the injection or injection of the molding material M starts after the molding device 30 has a first predetermined pressure.

In some embodiments, the pressure sensing unit 366 senses the pressure in the mold cavity 31 for atmospheric pressure. In some embodiments, the first valve 364 is opened, so the gas G is injected into the mold cavity 31 through the first gas conduit 361 . In some embodiments, when the feed port 35 is closed, the gas G is injected into the mold cavity 31 through the pressure regulating system 36 . In some embodiments, the gas G is injected into the mold cavity 31 through the feed port 35 .

In some embodiments, the pressure in the mold cavity 31 is continuously sensed while the gas G is injected into the mold cavity 31 . In some embodiments, the pressure sensing unit 366 continuously senses the pressure in the mold cavity 31, and injects the gas G into the mold cavity 31 until it senses that the mold cavity 31 has a first predetermined pressure; then, close the pressure regulating system 36 of the first valve 364 and the second valve 365, and stop the injection of gas G into the cavity 31. In some embodiments, the first predetermined pressure is greater than atmospheric pressure. In some embodiments, the first predetermined pressure is less than atmospheric pressure. In some embodiments, the size of the mold cavity 31 is 800 cc, and the first predetermined pressure is 25 kg/cm ³ . In some embodiments, the mold cavity 31 contains 20 liters of gas G.

In some embodiments, before step 913 or step 925, the mold cavity 31 has a first predetermined pressure, and both the first valve 364 and the second valve 365 of the pressure regulating system 36 are closed.

In some embodiments, please refer to FIG. 10 , the molding material M is injected or injected into the cavity 31 and makes the molding material M contact the flexible layer 22 . In some embodiments, the molding material M is expanded and foamed in the cavity 31 . After the molding material M is cured, the molding material M forms a foam structure 21 and contacts with the flexible layer 22 to form a composite 20b. In some embodiments, the flexible layer 22 covers part of the foam structure 21 . In some embodiments, part of the foam structure 21 is bonded to part of the flexible layer 22 inside the mold cavity 31 . In some embodiments, the foamed structure 21 and the flexible layer 22 fill the mold cavity 31 .

In some embodiments, during the injection or injection of the molding material M into the cavity 31 of the molding device 30, the pressure in the cavity 31 changes rapidly, and the pressure sensing unit 366 The pressure in the mold cavity 31 is sensed continuously. In some embodiments, the molding material M is injected or injected into the cavity 31 , and a first predetermined pressure is applied to the molding material M.

In some embodiments, the molding material M is injected or injected from the feed port 35 into the cavity 31 of the molding device 30 , thereby increasing the pressure in the cavity 31 . In some embodiments, the pressure in the mold cavity 31 of the molding device 30 rises above the first predetermined pressure. In some embodiments, the pressure in the cavity 31 of the molding device 30 rises from a first predetermined pressure to a second predetermined pressure.

In some embodiments, after injecting or injecting the molding material M into the mold cavity 31 with the first predetermined pressure, the pressure in the mold cavity 31 increases, therefore, the setting of the second predetermined pressure ensures that the mold cavity 31 is maintained at a suitable within the pressure range. In some embodiments, when the mold cavity 31 reaches the second predetermined pressure, the injection of the molding material M into the mold cavity 31 is stopped.

In some embodiments, the molding material M includes a predetermined ratio of polymer material and foaming agent. In some embodiments, the molding material M has a predetermined weight. In some embodiments, the process of injecting or injecting the molding material M into the cavity 31 with the first predetermined pressure lasts less than 1 second. In some embodiments, since the mold cavity 31 has the first predetermined pressure, the duration of the filling of the molding material M may be less than 0.5 seconds. During the injection or when the injection is completed, the pressure sensing unit 366 senses the pressure in the mold cavity 31 in real time, and provides pressure information, so that the pressure regulating system 36 can adjust the pressure in the mold cavity 31 according to the pressure information, and the mold cavity The pressure in 31 is maintained within a predetermined pressure range. In some embodiments, the temperature of the molding material M is higher than the temperature of the molding device 30 during the injection or injection process.

In some embodiments, after the step 913 or the step 925 , the method 910 and the method 920 further include discharging a part of the gas G from the cavity 31 after injecting the gas G into the cavity 31 . In some embodiments, the method 910 and the method 920 further include making the molding material M in the mold The cavity 31 is foamed, and when the molding material M is foamed in the cavity 31, at least a part of the gas G is discharged from the cavity 31 through the pressure regulating system 36 in less than 1 second. The foamed structure 21 formed from the molding material M after the foaming process may have a lower density due to at least a portion of the gas G being discharged. In some embodiments, at least a part of the gas G is discharged from the cavity 31 through the first gas conduit 361 and/or the second gas conduit 362 . In some embodiments, at least a portion of the gas G is exhausted from the cavity 31 during or after the foaming process of the molding material M. Referring to FIG. In some embodiments, the pressure in the mold cavity 31 is reduced from the second predetermined pressure while at least a portion of the gas G is vented.

For example, the size of the mold cavity 31 is 800cc, the first predetermined pressure is 25kg/cm3 (the mold cavity 31 includes 20L of gas G), and the gas G is discharged from the mold cavity 31 within 0.3 seconds to 0.6 seconds, and the speed of the exhaust gas G is 33L/sec to 66L/sec.

In some embodiments, when the pressure sensing unit 366 senses that the pressure in the cavity 31 is greater than the second predetermined pressure, part of the gas G in the cavity 31 is discharged until the pressure in the cavity 31 is within the predetermined pressure range Inside. In some embodiments, the predetermined pressure range is between a first predetermined pressure and a second predetermined pressure. In some embodiments, the first valve 364 is opened, and a part of the gas G in the mold cavity 31 is discharged through the first gas conduit 361 . In some embodiments, the second valve 365 is opened, and a part of the gas G in the mold cavity 31 is discharged through the second gas conduit 362 .

In some embodiments, method 910 and method 920 further include removing composite 20 b from forming device 30 . In some embodiments, referring to FIG. 11 , the first mold base 33 and the second mold base 32 are separated, and the compound 20b is further taken out from the molding device 30 . In some embodiments, the first mold base 33 is fixed, and the second mold base 32 is moved to separate the first mold base 33 and the second mold base 32 . In some embodiments, the second mold base 32 is fixed, and the first mold base 33 is moved to separate the first mold base 33 from the second mold base 32 .

12 and 13 are schematic diagrams of an injection molding system according to a specific embodiment of the present invention. In some embodiments, please refer to FIG. 12 and FIG. 13 , the molding material M is produced by the extrusion system 10 , and the extrusion system 10 directly injects the molding material M into the molding device 30 . In some embodiments, the extrusion system 10 injects the molding material M into the discharge channel 50 , and the molding material M is injected from the extrusion system 10 or injected into the molding device 30 through the discharge channel 50 . In some embodiments, the injection molding system 100 includes an extrusion system 10 , an exhaust channel 50 , and a molding device 30 . In some embodiments, extrusion system 10 corresponds to a plurality of discharge channels 50 . For the sake of clarity and simplicity, Figures 12 and 13 show two discharge channels 50 corresponding to one molding device 30, but this example is only intended to be illustrative and not intended to limit the embodiment.

In some embodiments, extrusion system 10 is connected or communicates with discharge channel 50 . The number of discharge passages 50 can be adjusted according to the properties of the molding material M. As shown in FIG. The discharge channels 50 extend parallel to each other and are arranged adjacent to each other. In some embodiments, each discharge channel 50 may contain the same or different amounts of molding material M. As shown in FIG. The discharge channels 50 may discharge the same or different amounts of molding material M into the molding device 30 . In some embodiments, each discharge channel 50 may accommodate the same or different weights of molding material M injected from the extrusion system 10 . In some embodiments, each discharge channel 50 may accommodate the same or a different volume of molding material M injected from the extrusion system 10 . The discharge channels 50 may discharge the same or different volumes of molding material M into the molding device 30 . In some embodiments, each exhaust channel 50 may operate at the same or a different temperature.

In some embodiments, each discharge channel 50 corresponds to a discharge port 51 remote from the extrusion system 10 . The material inlet 35 is configured to abut the material outlet 51 for extruding the molding material M into the material inlet 35 . In some embodiments, each outlet 51 may have the same or different width or diameter, so the molding material M may have the same or different flow rate at each outlet 51 . In some embodiments, the width or diameter of each outlet 51 corresponds to the row to which it belongs. Put channel 50 to adjust. In some embodiments, the outlet 51 can extrude molding materials M with different masses or volumes.

The discharge channels 50 can be moved, extended or retracted synchronously or individually. In some embodiments, outlet opening 51 of discharge channel 50 may extend into forming device 30 and retract from forming device 30 . In some embodiments, the discharge port 51 of the discharge channel 50 may extend into and retract from the corresponding feed port 35 .

In some embodiments, please refer to FIG. 12 , before injecting the molding material M into the mold cavity 31 , the extrusion system 10 and the discharge channel 50 are kept away from the molding device 30 . In some embodiments, extrusion system 10 and vent channel 50 are moved above mold cavity 31 . In some embodiments, extrusion system 10 and discharge channel 50 are positioned above molding device 30 . In some embodiments, the discharge channels 50 are aligned with corresponding openings 341 of the upper mold seat 34 of the molding device 30 .

In some embodiments, please refer to FIG. 13 , after the discharge channel 50 is aligned with the corresponding opening 341, the discharge channel 50 moves toward the molding device 30 until the discharge channel 50 is received by the corresponding opening 341 of the upper mold seat 34, and then the discharge Ports 51 are docked to corresponding feed ports 35 of forming device 30 . In some embodiments, the openings 341 of the upper mold base 34 are configured to receive corresponding discharge channels 50 . In some embodiments, the number of openings 341 corresponds to the number of discharge channels 50 . In some embodiments, the discharge channels 50 are moved vertically toward the molding device 30 such that the discharge channels 50 are received by corresponding openings 341 of the upper mold base 34 . In some embodiments, each discharge channel 50 is at least partially surrounded by the upper mold seat 34 , and the discharge ports 51 are respectively connected to the corresponding feed ports 35 .

After the discharge port 51 is docked with the corresponding feed port 35, the discharge port 51 and the corresponding feed port 35 form a flow channel for the molding material M, so that the discharge channel 50 communicates with the mold cavity 31 through the feed port 35, and the molding The material M is ready to be injected into the mold cavity 31 . The discharge port 51 must be connected with the corresponding feed port 35 tightly fit to prevent the molding material M from leaking out of the molding device 30.

In some embodiments, please refer to FIG. 14 , the extrusion system 10 for preparing molding material M includes a melting unit 120, a mixing unit 130, a foaming agent supply unit 140, an injection unit 150, a first flow control element 161, a second Two flow control components 162 and a monitoring module 180 .

In some embodiments, melting unit 120 is configured to deliver polymeric material. In some embodiments, the melting unit 120 includes a pressurized cartridge 121 , a first feed channel 122 , a first discharge channel 123 , and a pushing member 124 . In some embodiments, the melting unit 120 further includes a feed hopper 125 .

In some embodiments, the first feed channel 122 and the first discharge channel 123 are respectively configured at two ends of the pressurized box 121 . In some embodiments, the first feed channel 122 communicates with the inner space 1211 of the pressurized box 121, and the first discharge channel 123 communicates with the outer space of the pressurized box 121, wherein the first feed channel 122 is configured for The polymer material is delivered to the interior space 1211 of the pressurized cassette 121 . In some embodiments, feed hopper 125 is configured to deliver polymeric material through first feed channel 122 to interior space 1211 of pressurized cassette 121 .

The pushing member 124 is configured to convey polymer material from the first feed channel 122 to the first discharge channel 123 . In some embodiments, the pushing member 124 is disposed in the inner space 1211 of the pressurized box 121 . In some embodiments, the pushing member 124 is disposed in the inner space 1211 of the pressurized cartridge 121 between the first feed channel 122 and the first discharge channel 123 , and is used to push the polymeric material toward the first discharge channel 123 . In some embodiments, push member 124 is rotatable relative to pressurized cartridge 121 . In some embodiments, the polymeric material is conveyed from the first feed channel 122 to the first discharge channel 123 by rotation of the pusher member 124 . In some embodiments, the pushing member 124 cannot move in a direction parallel to the longitudinal axis of the pressurized box 121 .

In some embodiments, the length of the pushing member 124 extends along the length of the pressurized box 121, and the ratio of the shortest distance D1 between the inner sidewall 1212 of the pressurized box 121 and the pushing member 124 to the diameter D2 of the pushing member 124 is about 1. :1500 to about 1:4500, and the polymer material can be melted uniformly by the melting unit 120. In some embodiments, the shortest distance D1 between the inner sidewall 1212 of the pressurized box 121 and the pushing member 124 is approximately equal to or less than 0.3 mm. In some embodiments, the shortest distance D1 between the inner wall 1212 of the pressurized box 121 and the pushing member 124 is between 0.01 mm and 0.05 mm.

Mixing unit 130 is configured to receive polymeric material from melting unit 120 and to mix the polymeric material with a blowing agent to form a mixture of polymeric material and blowing agent. The mixing unit 130 includes a hollow mixing box 131 , a second feed channel 132 , a second discharge channel 133 and a mixing rotor 134 . In some embodiments, the mixture is the molding material M. In some embodiments, the molding material M is formed after the mixture of the polymer material and the foaming agent is uniformly mixed by the mixing unit 130 .

The second feed channel 132 and the second discharge channel 133 are respectively configured at two ends of the hollow mixing box 131 . In some embodiments, second feed channel 132 is configured to convey polymeric material. In some embodiments, the second discharge passage 133 is configured to convey the discharge mixture.

The mixing rotor 134 is configured to mix the polymeric material with the blowing agent to form a mixture within the hollow mixing cartridge 131 . In some embodiments, the mixing rotor 134 is disposed in the hollow mixing box 131 . In some embodiments, the mixing rotor 134 is disposed in the hollow mixing box 131 between the second feeding channel 132 and the second discharging channel 133 to stir the mixture in the hollow mixing box 131 . The mixing rotor 134 is rotatable to mix the polymer material and the blowing agent, and deliver the mixture of the polymer material and the blowing agent from the second feed channel 132 to the second discharge channel 133 . In some embodiments, the mixing rotor 134 cannot move parallel to the longitudinal axis of the hollow mixing box 131. move.

In some embodiments, the length of the mixing rotor 134 extends along the length of the hollow mixing box 131, and the ratio of the shortest distance D3 between the inner sidewall 1311 of the hollow mixing box 131 and the mixing rotor 134 to the diameter D4 of the mixing rotor 134 is about 1:1500 to about 1:4500, and the mixture produced by the extrusion system 10 can be consistent and uniform. In some embodiments, the mixture may be divided into a plurality of portions, and the ratio of blowing agent to polymeric material is substantially constant for each portion of the mixture produced by extrusion system 10 . In some embodiments, the ratio of polymeric material to blowing agent in the first location of the mixture is substantially equal to the ratio of polymeric material to blowing agent in the second location of the mixture. In some embodiments, the shortest distance D3 between the inner sidewall 1311 of the hollow mixing box 131 and the mixing rotor 134 is approximately equal to or less than 0.3 mm. In some embodiments, the shortest distance D3 between the inner wall 1311 of the hollow mixing box 131 and the mixing rotor 134 is between 0.01 mm and 0.09 mm.

15 is an enlarged view of a portion of an extrusion system according to aspects of the invention in some embodiments. In order to uniformly mix the melted polymer material and foaming agent in the hollow mixing box 131, in some embodiments, please refer to FIG. 14 and FIG. A cylindrical column body 1341 and a circular groove portion 1342 disposed on the periphery of the column body 1341 . Therefore, when the columnar body 1341 rotates, the polymer material and the foaming agent are stirred by the groove portion 1342, thereby obtaining a desired mixing effect. In some embodiments, the shortest distance D3 is the shortest distance between the groove portion 1342 and the inner sidewall 1311 of the hollow mixing box 131 .

In some embodiments, when the shortest distance D3 is the shortest distance between the groove portion 1342 and the inner wall 1311 of the hollow mixing box 131 , the shortest distance D3 is between 0.01 mm and 0.09 mm. In some embodiments, mixing rotor 134 has a diameter D4 between 45 and 75 mm. Table 1 The shortest distance D3, the diameter D4, and the corresponding ratio of the shortest distance D3 between the groove portion 1342 and the inner wall 1311 of the hollow mixing box 131 to the diameter D4 of the mixing rotor 134 are listed.

16 is a graph illustrating the relationship between the amount of foaming agent and the shortest distance in a mixture according to an embodiment of the present invention. In some embodiments, referring to FIG. 16 , when the shortest distance D3 is substantially less than 0.01 mm, the amount of blowing agent in the mixture is substantially greater than 0.8/cm ³ . In some embodiments, if the amount of blowing agent in the mixture is significantly greater than 0.8/cm ³ , the bubble density in the predetermined amount of mixture after foaming is significantly greater than 180,000/cm ³ .

17 is a graph illustrating the behavior of the ratio of blowing agent to polymer material versus the ratio of shortest distance to mixing rotor diameter, according to an embodiment of the present invention. In some embodiments, when the ratio of the shortest distance D3 to the diameter D4 is in the range between 1:1500 and 1:4500, the uniformity of the blowing agent and the polymer material is optimized. In other words, the mixing of blowing agent and polymer material by mixing rotor 134 is even and uniform. In some embodiments, when the ratio of the shortest distance D3 to the diameter D4 is in the range between 1:1500 and 1:4500, please refer to FIG. 17 , in a predetermined amount of mixture, the blowing agent and the polymer material The ratio is between 4:1 and 3:1. In some embodiments, the ratio of blowing agent to polymeric material in the predetermined amount of mixture is about 1:1. In some embodiments, if the ratio of foaming agent to polymer material in the predetermined amount of mixture is between 4:1 and 3:1, after foaming, in the predetermined amount of mixture, the air bubbles and polymer The ratio of materials is also between 4:1 and 3:1. In some embodiments, after foaming, the ratio of air bubbles to polymeric material in the predetermined amount of mixture is about 4:1.

In some embodiments, melting unit 120 includes a pressurized cartridge 121 configured to hold polymeric material and has a first pressure, and mixing unit 130 includes a hollow mixing cartridge 131 having a second pressure. In some embodiments, to prevent backflow, the first pressure is greater than the second pressure force. In some embodiments, the polymeric material is drawn from the melting unit 120 to the mixing unit 130 by the difference between the first pressure and the second pressure. In some embodiments, the sensor 182 of the monitoring module 180 senses the first pressure inside the melting unit 120 . In some embodiments, the sensor 182 of the monitoring module 180 senses the second pressure inside the mixing unit 130 .

The blowing agent supply unit 140 is connected to the mixing unit 130 and is configured to deliver the blowing agent into the mixing unit 130 . In some embodiments, the blowing agent supply unit 140 is located between the first flow control element 161 and the second flow control element 162 . In some embodiments, the blowing agent supply unit 140 is disposed close to the first flow control element 161 and away from the second flow control element 162 .

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

In some embodiments, the first flow control element 161 is disposed at the first interface 171 connecting the melting unit 120 to the mixing unit 130 . The first interface 171 is configured to introduce polymer material from the melting unit 120 into the mixing unit 130 . The first interface 171 is located between the melting unit 120 and the mixing unit 130 . In some embodiments, the first interface 171 is configured to introduce polymer material from the pressurized cartridge 121 of the melting unit 120 into the hollow mixing cartridge 131 of the mixing unit 130 . In some embodiments, the polymeric material is conveyed and/or drawn from the melting unit 120 to the mixing unit 130 through the first port 171 using the difference between the first pressure and the second pressure.

In some embodiments, first flow control element 161 is disposed between melting unit 120 and mixing unit 130 and is configured to control the flow of the polymer material from melting unit 120 to mixing unit 130 . The first flow control element 161 can be a valve, a movable upper cover, and the like.

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

In some embodiments, first flow control element 161 is configured to maintain a pressure differential between melting unit 120 and mixing unit 130 . In some embodiments, the first flow control element 161 is configured to maintain a pressure differential between the melting unit 120 and the mixing unit 130 by switching between an open configuration and a closed configuration such that the polymeric material cannot escape from mixing. The hollow mixing cartridge 131 of the unit 130 flows back to the pressurized cartridge 121 of the melting unit 120 . In some embodiments, the first flow control element 161 is configured to regulate the first pressure and/or the second pressure to maintain a pressure differential between the first pressure and the second pressure. In some embodiments, the first flow control element 161 is in the closed configuration when the first pressure is similar to the second pressure.

In some embodiments, the injection unit 150 is configured to receive the mixture discharged from the second discharge channel 133 of the mixing unit 130 and discharge the mixture from the injection unit 150 . In some embodiments, the injection unit 150 is configured to inject the mixture, and the discharge channel 50 communicates with the injection unit 150 .

In some embodiments, the firing unit 150 includes a hollow metering cartridge 151 configured to contain the mixture. The hollow metering cartridge 151 has a hollow interior space 1511, wherein the interior space 1511 communicates with the second discharge passage 133 and is configured to contain a mixture. The injection unit 150 also includes a connecting passage 152 communicating with the inner space 1511 of the hollow metering box 151, and a discharge discharge slidably arranged in the inner space 1511 of the hollow metering box 151 and configured to discharge the mixture from the hollow metering box 151 through the outlet 154. Member 153.

In some embodiments, the monitoring module 180 is configured to monitor the extrusion system in real time. System 10. In some embodiments, the monitoring module 180 includes a central processing unit 181 and a sensor 182 electrically connected or communicable with the central processing unit 181 . In some embodiments, a plurality of sensors 182 are placed throughout extrusion system 10 and are configured to sense at least one process condition (e.g., flow rate or viscosity of polymer material along melt unit 120, The amount of molding material M accumulated in the melting unit 120, the first pressure in the mixing unit 130, the third pressure in the injection unit 150, the pressure difference between the first pressure and the second pressure, the first pressure The pressure difference between the second pressure and the third pressure, the temperature of each unit, the rotating speed of the pushing member 124 and the mixing rotor 134, or the flow rate and amount of the blowing agent through the blowing agent supply unit 140), can be for example but not Placed at predetermined positions of the extrusion system 10 (for example, the melting unit 120, the mixing unit 130, the injection unit 150, the foaming agent supply unit 140, the first port 171, the second port 172, the outlet 154, the first flow control element 161 or second flow control element 162). For example, at least one sensor 182 is installed at each unit for sensing process conditions of the corresponding unit. In some embodiments, the sensors 182 are configured to detect processing conditions and transmit signals or data based on the detected processing conditions to the central processor 181 for further analysis. The number of sensors 182 can be adjusted as desired.

In some embodiments, the monitoring module 180 can automatically monitor and real-time adjust the processing conditions of corresponding positions of the extrusion system 10 according to the processing conditions sensed by the sensor 182 and/or the analysis of the central processing unit 181 . The sensor 182 is not limited to any particular type as long as it can sense processing conditions and provide information upon sensing. The central processing unit 181 changes the processing conditions based on this information, thereby adjusting the processing conditions of each unit so that the molding material M thus produced has desired predetermined characteristics.

In some embodiments, the extrusion method of the molding material M comprising a polymer material and a blowing agent comprises, transferring the polymer material from the melting unit 120 to the mixing unit 130, The foaming agent is transferred from the foaming agent supply unit 140 to the mixing unit 130 where the polymeric material and the foaming agent are mixed to form the molding material M. Referring to FIG. The method also includes transferring the molding material from the mixing unit 130 to the injection unit 150 , and discharging the molding material M from the injection unit 150 . In some embodiments, the molding material M enters the discharge channel 50 from the injection unit 150 , and then enters the molding device 30 from the discharge channel 50 .

In some embodiments, please refer back to FIG. 12 and FIG. 13 , the injection molding system 100 further includes a control system 60 . Control system 60 is configured to control extrusion system 10 , discharge channel 50 and molding device 30 . In some embodiments, control system 60 is configured to control extrusion system 10 , discharge channel 50 , and forming device 30 on the fly. In some embodiments, the control system 60 can communicate with the monitoring module 180 of the extrusion system 10 in real time.

In some embodiments, the control system 60 includes a central processing unit 61 and a plurality of sensors 62 electrically connected to or in communication with the central processing unit 61 . In some embodiments, the sensor 62 is placed in the entire injection molding system 100 and configured to be at a predetermined position of the injection molding system 100 (for example, the discharge channel 50 and the molding device 30, the discharge port 51, the feed port 35 and the alignment of the cavity 31, etc.), sensing at least one processing condition (for example, the flow rate or viscosity of the molding material M passing through the discharge channel 50, the amount of the molding material M discharged from the discharge channel 50, the pressure inside the cavity 31 wait). For example, at least one sensor 62 is installed at the outlet 51 for sensing the processing condition at the outlet 51 . In some embodiments, the sensor 62 is configured to detect the processing condition and based on the detected processing condition, send a signal or data to the central processing unit 61 for further analysis.

In some embodiments, control system 60 controls when discharge channel 50 interfaces with forming device 30 . In some embodiments, a cable 63 is electrically connected between the control system 60 and the extrusion system 10 , the discharge channel 50 and the forming device 30 . Cable 63 is configured to transfer signals from the shaping device 30 to the extrusion system 10 and discharge channel 50.

In some embodiments, the control system 60 is configured to process the pressure information detected by the pressure sensing unit 366 and to adjust the mixing conditions of the extrusion system 10 and the amount and timing of extrusion of the discharge channel 50 . In some embodiments, the pressure sensing unit 366 provides pressure information to the control system 60, and the control system 60 adjusts the first valve 364 and the second valve 365 according to the pressure information. In some embodiments, the control system 60 adjusts the state of the gas entering/leaving the cavity 31 in real time according to the pressure information, and adjusts the timing and amount of injection of the molding material M from the discharge channel 50 to the cavity 31. Therefore, in the injection molding process , the injection volume and the injection rate are within an appropriate or predetermined range, and the pressure in the mold cavity 31 is always within an appropriate or predetermined pressure range. In some embodiments, the control system 60 further controls the feed conditions of the feed port 35 and the gas supply conditions of the gas source 363 . In some embodiments, the control system 60 is electrically connected to the first valve 364 , the second valve 365 , the pressure sensing unit 366 and the feed port 35 .

In some embodiments, the injection molding system 100 further includes a supporting device 40 . The support device 40 is configured to facilitate the engagement of the discharge channel 50 and the forming device 30 . The support device 40 may be located at any suitable location of the injection molding system 100 .

In some embodiments, support device 40 is configured to support discharge channel 50 . In some embodiments, the supporting device 40 is used to prevent the discharge channel 50 from being separated from the molding device 30 during injection of the molding material M. In some embodiments, control system 60 controls support device 40 on the fly.

In some embodiments, the support device 40 includes a first element 41 and a second element 42 configured to engage with each other, wherein the first element 41 protrudes from the extrusion system 10 or the discharge channel 50, and the second element 42 is placed in the molding device Each of 30, but this work is not limited thereto. In some embodiments, the first element 41 and the second element 42 may be clamped to each other; for example, the second element 42 is configured to receive the first element 41 .

In some embodiments, the supporting device 40 is placed above the cavity 31 of the molding device 30 . In some embodiments, the first element 41 is placed on the discharge channel 50 and the second element 42 is placed on the forming device 30 . In some embodiments, the second element 42 is placed on the upper mold seat 34 of the molding device 30 . In some embodiments, first element 41 is part of extrusion system 10 or discharge channel 50 , while second element 42 is part of molding device 30 . In some embodiments, the first element 41 is part of the extrusion system 10 while positioned adjacent to the discharge channel 50 and the second element 42 is positioned on or facing the upper die seat 34 of the molding device 30 . In some embodiments, the first member 41 and the second member 42 may engage each other to tightly engage the discharge channel 50 with the upper mold seat 34 of the molding device 30 .

In some embodiments, to prevent separation of extrusion system 10 and molding device 30 during injection of molding material M, engaged first element 41 is forced against second element 42 . The force is equal to or greater than a threshold. The threshold can be adjusted according to the pressure in the mold cavity 31 and the diameter of the outlet opening 51 or according to other factors.

The position and quantity of the first elements 41 can be adjusted as required, without any special limitation. The position and quantity of the second element 42 can also be adjusted as required, without any special limitation. In some embodiments, the location and number of the second elements 42 correspond to the location and number of the first elements 41 . In some embodiments, first element 41 may be placed at any suitable location on discharge channel 50 and second element 42 may be placed at any suitable location on forming device 30 . In some embodiments, the second element 42 is placed on the second mold base 32 .

18 and 19 are schematic diagrams of a portion of an injection molding system 100 according to an embodiment of the present invention. In some embodiments, please refer to FIG. 18 , the supporting device 40 can be in one of two states, namely a locked state and an unlocked state. In the unlocked state, the first element 41 enters into the corresponding second element 42 but is not yet locked by the second element 42 . In other words, when supporting When the device 40 is in the unlocked state, the first element 41 can still be withdrawn from the second element 42 . In the locked state, the first element 41 enters and locks with the corresponding second element 42 such that the first element 41 cannot withdraw from the second element 42 . FIG. 18 illustrates the support device 40 in a locked state. The support device 40 can be operated and controlled manually or automatically. The support device 40 can switch between the two states manually or automatically.

In some embodiments, first element 41 is rotationally fixed to extrusion system 10 . In some embodiments, please refer to FIG. 19 , the first element 41 includes an elongated portion 411 and an arm portion 412 . The elongated portion 411 and the arm portion 412 are rotatable in the direction indicated by arrow A. As shown in FIG. The elongated portion 411 is fixed to the extrusion system 10 and extends along the first direction Z towards the second die base 32 . The arm portion 412 is coupled to the elongated portion 411 and extends in a second direction X substantially perpendicular to the first direction Z, or in a third direction Y substantially perpendicular to the first direction Z. In some embodiments, the first element 41 has an inverted T shape. After the first element 41 enters the second element 42, by rotating the arm portion 412 of the first element 41, the supporting device 40 changes from an unlocked state to a locked state. In some embodiments, the first element 41 and the second element 42 are locked by rotating the arm portion 412 of the first element 41 by about 90 degrees. FIG. 19 illustrates that the arm 412 is locked with the second member 42 after the arm 412 has been rotated approximately 90 degrees. As a result, the support device 40 is in a locked state, and the discharge channel 50 is closely engaged with the molding device 30 , and thus the molding material M can start to be ejected from the extrusion system 10 and the discharge channel 50 to the molding device 30 .

20 to 22 are top views of a composite according to an embodiment of the present invention. In some embodiments, the composite 20a, 20b is a cushion, such as, but not limited to, a seat cushion. In some embodiments, the composite 20a, 20b is a seat cushion for a vehicle, such as, but not limited to, a bicycle seat cushion. In some embodiments, please refer to FIG. 20 to FIG. 22 , after the composites 20a, 20b are formed by the method 910 or the method 920, the foam structure 21 thereof may have textures on the surface. 210. In some embodiments, the texture 210 is formed on the first surface 211 .

The texture 210 can be produced due to the following reasons: (1) pre-injection of the gas G in the mold cavity 31 (before the injection molding material M, the gas is filled into the mold cavity 31), due to the pre-injected gas G, the foam structure 21 the texture 210 formed on the surface; (2) the texture 210 formed due to the injection molding material M into the mold cavity 31; (3) the texture 210 of the injection molding material M formed at the position P corresponding to the feed port 35; ( 4) the number of positions P where the material M is injected; and/or (5) the shape of the mold cavity 31 . In some embodiments, the texture 210 presented on the surface of the foam structure 21 can reflect a variety of light with different wavelengths.

In some embodiments, please refer to FIG. 20 , the first surface 211 has a position P. As shown in FIG. In some embodiments, the position P corresponds to the feed port 35 , and the foam structure 21 is formed by injecting the molding material M into the mold cavity 31 through a feed port 35 . The texture 210 extends from the position P to match the shape of the foam structure 21 . In some embodiments, position P is located at the center of texture 210 .

In some embodiments, please refer to FIG. 21 , there are two injection molding material M locations P1 and P2. Position P1 is adjacent to position P2. In some embodiments, the positions P1 and P2 are positions corresponding to the feed ports 35 , and the foam structure 21 is formed by injecting the molding material M into the mold cavity 31 through the two feed ports 35 . Texture 210 may extend from position P1 and position P2. In some embodiments, the texture 210 is formed by distributing outward from the center of the position P1 and the position P2 . The texture 210 distributed from the position P1 may conform to the shape of the mold cavity 31 and be affected by the molding material M injected from the position P2. The texture 210 distributed from the position P2 may conform to the shape of the mold cavity 31 and be affected by the molding material M injected from the position P1.

In some embodiments, please refer to FIG. 22 , there are three positions P1 , position P2 and position P3 for injecting the molding material M. In some embodiments, position P2 is located between position P1 and position between P3. In some embodiments, the position P1 , the position P2 and the position P3 are positions corresponding to the feed ports 35 , and the foam structure 21 is formed by injecting the molding material M into the mold cavity 31 through the three feed ports 35 . In some embodiments, the positions P1 , P2 and P3 are arranged in a line or an arc. In some embodiments, the texture 210 is formed by distributing outward from the center of the position P1 , the position P2 and the position P3 . The texture 210 can extend from the position P1 , the position P2 and the position P3 . The texture 210 distributed from the position P1 may conform to the shape of the mold cavity 31 and be affected by the molding material M injected from the position P2. The texture 210 distributed from the position P2 may conform to the shape of the mold cavity 31 and be affected by the molding material M injected from the positions P1 and P3. The texture 210 distributed from the position P3 may conform to the shape of the mold cavity 31 and be affected by the molding material M injected from the position P2.

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

Furthermore, the scope of the invention is not limited to the specific embodiments of the procedures, machines, manufacturing, material composition, components, methods and steps described in the specification. From the disclosure content of this creation, those who are familiar with this technology will easily understand that according to this creation, programs that currently exist or will be developed in the future can be used to implement the same functions as the corresponding specific embodiments described herein or to obtain substantially the same results , machine, manufacture, composition of matter, member, method or step. Accordingly, the claims of the appended applications are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods and steps.

20a: Complex

21: Foam structure

22: flexible layer

211: first surface

212: second surface

Claims (10)

A compound includes: a flexible layer and a foam structure including molding material, the flexible layer includes a surface, and the foam structure overlaps and connects with at least a part of the surface of the flexible layer. The compound according to claim 1, wherein the compound is conformal to a molding cavity defined by a first mold base and a second mold base. The composite of claim 1, wherein the flexible layer is softened. The composite of claim 2, wherein the molding cavity includes a first cavity of the first mold base and a second cavity of the second mold base, and the flexible layer is in contact with the first cavity The inner wall is conformal. The composite of claim 1, wherein the molding material comprises a polymer material and a foaming agent. The composite according to claim 2, further comprising: textures located on the molding material, the position and shape of the textures corresponding to the shape of the molding cavity and a feed port communicating with the molding cavity. The composite of claim 1, wherein the flexible layer is stretched. A molding device for preparing a composite comprising a molding material and a flexible layer, comprising: A first mold base; a second mold base, which can be matched with the first mold base; and a molding cavity defined by the first mold base and the second mold base, the forming mold cavity includes the first mold base a first mold cavity defined by a mold base and a second mold cavity defined by the second mold base; wherein an inner wall of the first mold cavity is configured to push at least a portion of the flexible layer toward or Pulling toward the inner wall, the molding cavity is used to inject the molding material, and make the at least a part of the flexible layer contact the molding material in the molding cavity to form the compound. The molding device according to claim 8, wherein the flexible layer can be fixed between the first mold base and the second mold base. The molding device according to claim 8, further comprising: a pressure regulating system communicated with the molding cavity for pushing or pulling the at least a part of the flexible layer toward the inner wall by a gas.

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