Patent Description:
The present invention is related to an injection-molding system and an injection-molding method, and, in particular, to an injection molding system and an injection molding method for making a foamed polymeric article.

Foamed polymer articles have many advantages, such as high strength, light weight, impact resistance, good sound insulation and thermal insulation, etc. The foamed polymer article can be made into a molded article having a predetermined shape by injection molding or extrusion molding. For example, after a polymeric material is melted and mixed with a blowing agent in an extruding system to form a flowable mixture, the mixture is injected or extruded into a molding device to form the desired foamed polymer article. The properties and qualities of foamed polymer articles can be improved by adjusting the structure of the injection molding system and adjusting the injection molding system.

<CIT> discloses an injection moulding unit according to the preamble of claim <NUM> and an injection moulding method.

One purpose of the present invention is to provide an injection-molding system and a method of injection molding.

According to one embodiment of the present disclosure, an injection molding system is disclosed. The injection molding system includes a supplying unit configured to supply a flowable mixture of a polymeric material and a blowing agent; an injection unit communicable with the supplying unit, wherein the injection unit includes an outlet disposed distal from the supplying unit and configured to discharge the flowable mixture; a molding device configured to receive the flowable mixture from the outlet and including a mold cavity and an opening communicable with the mold cavity and correspondingly engageable with the outlet; and a supporting device configured to facilitate an engagement of the injection unit and the molding device. The supporting device includes a first element connected to the injection unit and a second element disposed on the molding device. The second element includes a slot configured to receive a protruding portion of the first element, the protruding portion of the first element is slidable within and along the slot of the second element.

According to one embodiment of the present disclosure, an injection molding method is disclosed. The molding method includes: providing an injection molding system, wherein the injection molding system includes an injection unit and the molding device, the injection unit includes an outlet configured to discharge a flowable mixture, and the molding device is configured to receive the flowable mixture from the outlet and includes a mold cavity and an opening communicable with the mold cavity and correspondingly engageable with the outlet; providing a supporting device configured to facilitate an engagement of the injection unit and the molding device, wherein the supporting device includes a first element connected to the injection unit and a second element disposed on the molding device; aligning a protruding portion of the first element with a slot of the second element; displacing the molding device toward the injection unit to slide the protruding portion of the first element along the slot of the second element; engaging the outlet with the opening when the protruding portion of the first element is engaged with the slot of the second element; and injecting the flowable mixture into the mold cavity.

It should be noted that, in accordance with the standard practice in the industry, various features are not drawn to scale.

The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature over or on 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.

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 the respective testing measurements. Also, as used herein, the term "about" generally means within <NUM>%, <NUM>%, <NUM>%, or <NUM>% of a given value or range. Alternatively, the term "about" means within an acceptable standard error of the mean when considered by one of ordinary skill in the art. Other than in the operating/working examples, or unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages such as those for quantities of materials, durations of times, temperatures, operating conditions, ratios of amounts, and the likes thereof disclosed herein should 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 disclosure and attached claims are approximations that can 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. All ranges disclosed herein are inclusive of the endpoints, unless specified otherwise.

In general, the appearance and physical properties of the foamed polymer articles are directly affected by the injection molding process, and hence, the design of the injection molding system must consider the injection condition of the flowable mixture from the injection unit into the molding device so that the flowable mixture can be injected in the molding device completely and effectively so as to form the foamed polymer article with desirable quality.

<FIG> illustrates a schematic perspective view of a first injection molding system <NUM> according to an embodiment of the present disclosure. In some embodiments, referring to <FIG>, the first injection molding system <NUM> includes an injection unit <NUM> and a molding device <NUM>. The injection unit <NUM> is engageable with the molding device <NUM>. In some embodiments, the first injection molding system <NUM> further includes a flowable mixture supplying unit <NUM> communicable with the injection unit <NUM>. In some embodiments, the flowable mixture supplying unit <NUM> is configured to produce and supply a flowable mixture to the injection unit <NUM>.

In some embodiments, the flowable mixture includes a polymeric material such as ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethanes (TPU), thermoplastic polyester elastomer (TPEE) or the like. In some embodiments, the flowable mixture includes a recyclable material. In some embodiments, the flowable mixture further includes a blowing agent. In some embodiments, the blowing agent can be any type of chemical or physical blowing agent known to those of ordinary skill in the art. In some embodiments, the blowing agent is a supercritical fluid. The supercritical fluid may include inert gas such as carbon dioxide or nitrogen in supercritical state. In some embodiments, the flowable mixture contains polymeric material in a molten state and the blowing 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 supplying unit <NUM> of the first injection molding system <NUM> includes an extruder (not shown) for converting the polymeric material into the molten state and a mixer (not shown) for mixing the blowing agent into the polymeric material. The polymeric material is flowable from the extruder into the mixer.

In some embodiments, the injection unit <NUM> includes an injector 101a. In some embodiments, more than one injector 101a can be included in the injection unit <NUM>. In some embodiments, the injector 101a is configured to receive the flowable mixture from the flowable mixture supplying unit <NUM> and discharge the flowable mixture from an outlet 101c. In some embodiments, the injector 101a is in a configuration of a discharging channel and the outlet 101c is disposed distal to the injector 101a and configured to discharge the flowable mixture.

In some embodiments, the injector 101a is communicable with the mixer or the flowable mixture supplying unit <NUM>. In some embodiments, the flowable mixture is discharged from the injector 101a into the molding device <NUM>. The injector 101a is engageable with the molding device <NUM>. The injector 101a is extendable towards the molding device <NUM> and retractable from the molding device <NUM>. In some embodiments, the injector 101a is vertically extendable/retractable in a first direction as shown by an arrow A. In some embodiments, the injector 101a is extendable/retractable by a hydraulic mechanism 101e. In some embodiments, the hydraulic mechanism 101e attaches to the injector 101a. In some embodiments, the hydraulic mechanism 101e is disposed between the flowable mixture supplying unit <NUM> and the injector 101a.

In some embodiments, a supporting device <NUM> is configured to facilitate an engagement of the injection unit <NUM> and the molding device <NUM>. In some embodiments, the supporting device <NUM> is disposed over the molding device <NUM>. In some embodiments, the supporting device <NUM> include a first element 101b disposed adjacent to the injector 101a. In some embodiments, the first element 101b is connected to the injection unit <NUM>. The first element 101b is extendable towards the molding device <NUM> and retractable from the molding device <NUM>. In some embodiments, the first element 101b is vertically extendable/retractable in a second direction as shown by an arrow B. In some embodiments, the first direction and the second direction are in parallel.

In some embodiments, the first element 101b is extendable/retractable along a rail 101f by a motor (not shown) or the like. In some embodiments, the rail 101f is disposed between the flowable mixture supplying unit <NUM> and the first element 101b. In some embodiments, the injector 101a and the first element 101b are extendable/retractable independent from each other. The injector 101a and the first element 101b can be displaced relative to each other. In some embodiments, the injector 101a and the first element 101b can be displaced separately or consistently. In some embodiments, the first element 101b is in a T shape. In some embodiments, the first element 101b includes a protruding portion 101d engageable with the molding device <NUM>. In some embodiments, the protruding portion 101d of the first element 101b is disposed distal to the flowable mixture supplying unit <NUM>.

In some embodiments, the injection unit <NUM> is disposed above the molding device <NUM>. In some embodiments, the injector 101a and the first element 101b are disposed above the molding device <NUM>. In some embodiments, the molding device <NUM> is configured to receive the flowable mixture discharged from the injector 101a through the outlet 101c.

In some embodiments, the molding device <NUM> includes a first mold 102c and a second mold 102d engageable with the first mold 102c. In some embodiments, the first mold 102c is an upper mold, and the second mold 102d is a lower mold. In some embodiments, the molding device <NUM> includes a mold cavity (not shown) defined by the first mold 102c and the second mold 102d, and an opening (not shown) in communicable with the mold cavity and correspondingly engageable with the outlet 101c.

<FIG> illustrates a schematic perspective view of a second element <NUM> of the supporting device <NUM>, and <FIG> illustrates a schematic top view of the second element <NUM>. In some embodiments, referring to <FIG>, the supporting device <NUM> includes the second element <NUM> disposed on the molding device <NUM> and engageable with the first element 101b. In some embodiments, the second element <NUM> is engageable with the molding device <NUM>. In some embodiments, the second element <NUM> is engageable with the first mold 102c. In some embodiments, the second element <NUM> is removably attached to the molding device <NUM>. In some embodiments, the second element <NUM> includes a slot 102e defined by a protrusion 102f.

In some embodiments, the slot 102e and the protrusion 102f are laterally elongated. The slot 102e is configured to receive the protruding portion 101d of the first element 101b of the injection unit <NUM>. The protruding portion 101d of the first element 101b is engageable with the protrusion 102f. In some embodiments, the protruding portion 101d of the first element 101b is slidable within and along the slot 102e of the second element <NUM>. In some embodiments, a length L1 of the slot 102e equals to a width W1 of the second element <NUM>. In some embodiments, a height H1 of the slot 102e is greater than a thickness T1 of the protruding portion 101d of the first element 101b. 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 102f.

In some embodiments, the second element <NUM> includes a groove <NUM> configured to receive the outlet 101e. In some embodiments, the groove <NUM> is disposed in the second element <NUM> and laterally elongated along the second element <NUM>. In some embodiments, the groove <NUM> is in parallel to the protrusion 102f and the slot 102e. In some embodiments, the groove <NUM> is disposed between the first portion 102x and the second portion 102y of the protrusion 102f. The groove <NUM> is configured to receive the outlet 101c or an end portion of the injector 101a of the injection unit <NUM>. The outlet 101c or the end portion of the injector 101a is slidable within and along the groove <NUM>. In some embodiments, an opening <NUM> is disposed within the groove <NUM>. The opening <NUM> extends through the second element <NUM>.

In some embodiments, the outlet 101c or the end portion of the injector 101a is receivable by the opening <NUM>. The outlet 101c or the end portion of the injector 101a is movable within the opening <NUM>. In some embodiments, a width W3 of the opening <NUM> is substantially greater than a width W2 of the outlet 101c of the injector 101a. In some embodiments, the width W3 of the opening <NUM> equals to the width W2 of the outlet 101c of the injector 101a.

In some embodiments, a width W4 of the groove <NUM> is substantially greater than the width W3 of the opening <NUM>. In some embodiments, a step <NUM> is formed within the groove <NUM> and adjacent to the opening <NUM>. In some embodiments, the outlet 101c or the end portion of the injector 101a may dispose on the step <NUM> while the molding device <NUM> is receiving the flowable mixture. In some embodiments, the width W3 of the opening <NUM> is substantially less than the width W2 of the outlet 101c of the injector 101a, and the outlet 101c or the end portion of the injector 101a may disposed on the step <NUM> when the outlet 101c or the end portion of the injector 101a is engaged with the second element <NUM>. In some embodiments, the outlet 101c covers the opening <NUM> when the outlet 101c or the end portion of the injector 101a is engaged with the second element <NUM>.

In some embodiments, a first sensor <NUM> is disposed within the slot 102e and configured to sense a contact of the protruding portion 101d of the first element 101b and the second element <NUM>. In some embodiments, the first sensor <NUM> is disposed at the middle end of the slot 102e. In some embodiments, the first sensor <NUM> is disposed within the slot 102e and adjacent to the opening <NUM>. The first sensor <NUM> is not limited to any particular type, as long as it can sense the pressure and provide pressure information. In some embodiments, a plurality of first sensors <NUM> are disposed within the slots 102e, and the first sensors <NUM> are configured to sense a position and the contact of the protruding portion 101d and the slot 102e. The number and location of the plurality of first sensors <NUM> are not particularly limited; for example, they can be arranged at anywhere of the protrusion 102f and within the slot 102e; however, the present invention is not limited thereto.

In some embodiments, a second sensor <NUM> is disposed within the groove <NUM> and configured to sense a contact of the outlet 101c and the molding device <NUM>. In some embodiments, a second sensor <NUM> is disposed within the groove <NUM> and adjacent to the opening <NUM>. The second sensor <NUM> is not limited to any particular type, as long as it can sense the pressure and provide pressure information. In some embodiments, a plurality of second sensors <NUM> are disposed within the groove <NUM>, and the second sensors <NUM> are configured to sense a position and the contact of the outlet 101c and the groove <NUM>. The number and location of the plurality of second sensors <NUM> are not particularly limited; for example, they can be arranged at anywhere of the groove <NUM>; however, the present invention is not limited thereto.

In some embodiments, the molding device <NUM> can be in an open state and a closed state. The first mold 102c is engaged with the second mold 102d when the molding device <NUM> is in the closed state. <FIG> illustrates a schematic perspective view of the molding device <NUM> in a closed state, and <FIG> illustrates a schematic cross-sectional view of the molding device <NUM> in the closed state.

In some embodiments, referring to <FIG>, a mold cavity 102i is defined by the first mold 120c and the second mold 102d when the molding device <NUM> 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 <NUM> of the second element <NUM>. The mold cavity 102i is accessible only through a feeding port 102j when the molding device <NUM> is in the closed state. The mold cavity 102i is accessible through a gap (not shown) between the first mold 102c and the second mold 102d when the molding device <NUM> is in the open state. In some embodiments, the molding device <NUM> includes the feeding port 102j communicable with the mold cavity 102i. In some embodiments, the feeding port 102j is disposed at and penetrates through the first mold 102c. In some embodiments, the opening <NUM> is aligned with the feeding port 102j when the second element <NUM> is disposed over the molding device <NUM>, so that the flowable mixture can flow from the injector 101a into the mold cavity 102i through the opening <NUM> and the feeding port 102j. In some embodiments, the opening <NUM> is overlapped with the feeding port 102j when the second element <NUM> is disposed over the molding device <NUM> from a top view.

In some embodiments, the molding device <NUM> is disposed on a carrier (not shown) and may be moved together with the carrier. In some embodiments, a plurality of molding devices <NUM> are disposed on the carrier, and the molding devices <NUM> are arranged in a line, a row, a column, an arc, a curve or any other suitable arrangements. In some embodiments, the carrier is rotatable.

In some embodiments, referring back to <FIG>, <FIG>, the supporting device <NUM> further includes a third element <NUM> connected to the injection unit <NUM>, and the second element <NUM> is configured to receive the first element 101b and the third element <NUM>. In some embodiments, the first element 101b and the third element <NUM> are both configured to receive by the first portion 102x and the second portion 102y of the protrusion 102f.

In some embodiments, the third element <NUM> is disposed adjacent to the injector 101a. In some embodiments, the third element <NUM> is connected to the injection unit <NUM>. In some embodiments, the injector 101a is disposed between the first element 101b and the third element <NUM>. The third element <NUM> is engageable with the second element <NUM>. The third element <NUM> is extendable towards the second element <NUM> and retractable from the second element <NUM>. In some embodiments, the third element <NUM> is vertically extendable/retractable in the second direction as shown by the arrow B.

In some embodiments, the third element <NUM> is extendable/retractable along the rail 101f by a motor (not shown) or the like. In some embodiments, the rail 101f is disposed between the flowable mixture supplying unit <NUM> and the third element <NUM>. In some embodiments, the third element <NUM> and the first element 101b are extendable/retractable independent from each other. The third element <NUM> and the first element 101b can be displaced relative to each other. In some embodiments, the third element <NUM> and the injector 101a are extendable/retractable independent from each other. The third element <NUM> and the injector 101a can be displaced relative to each other. In some embodiments, the third element <NUM> and the first element 101b can be displaced separately or consistently. In some embodiments, the third element <NUM> is in a T shape. In some embodiments, the third element <NUM> includes a protruding portion <NUM> engageable with the second element <NUM>. In some embodiments, the protruding portion <NUM> is engageable with the slot 102e. In some embodiments, the protruding portion <NUM> of the third element <NUM> is disposed distal to the flowable mixture supplying unit <NUM>. In some embodiments, a configuration of the third element <NUM> is similar to or different from a configuration of the first element 101b.

In the present disclosure, a first injection molding method <NUM> is also disclosed. The first injection molding method <NUM> includes a number of operations, and the description and illustrations are not deemed as a limitation of the sequence of the operations. <FIG> is an embodiment of the first injection molding method <NUM>. In some embodiments, the first injection molding method <NUM> includes a number of operations (<NUM> to <NUM>). <FIG> are schematic cross-sectional views of various stages of the first injection molding method in accordance with some embodiments of the present disclosure. In some embodiments, the first injection molding method <NUM> is implemented by the first injection molding system <NUM> as illustrated in <FIG> and discussed above.

In operation <NUM>, referring to <FIG>, a first injection molding system <NUM> including an injection unit <NUM>, a molding device <NUM> and a supporting device <NUM> is provided. In some embodiments, the first injection molding system <NUM> includes the injection unit <NUM>, the molding device <NUM> and the supporting device <NUM> as discussed above. The molding device <NUM> is in the closed state. The opening <NUM> of the second element <NUM> is aligned with a feeding port 102j of the molding device <NUM>, so that the mold cavity 102i is accessible through the opening <NUM> and the feeding port 102j. In some embodiments, the molding device <NUM> is disposed on a carrier (not shown) and may be moved together with the carrier. In some embodiments, several molding devices <NUM> are disposed on the carrier.

In operation <NUM>, a protruding portion 101d of a first element 101b of the supporting device <NUM> is aligned with a slot 102e of the second element <NUM> of the supporting device <NUM>. In operation <NUM>, an outlet 101c is aligned with a groove <NUM> of the second element <NUM> configured to receive the outlet 101c. In some embodiments, the alignment of the protruding portion 101d of the first element 101b with the slot 102e of the second element <NUM> and the alignment of the outlet 101c with the groove <NUM> are performed simultaneously. In some embodiments, the molding device <NUM> is disposed under the second element <NUM> during the alignment of the protruding portion 101d of the first element 101b with the slot 102e of the second element <NUM>.

In some embodiments, the injector 101a and the first element 101b are vertically displaced along the arrow A and the arrow B respectively in order to horizontally align with the groove <NUM> and the slot 102e respectively as shown in <FIG>. In some embodiments, the injector 101a moves upward or downward in order to horizontally align the outlet 101c with the groove <NUM>. In some embodiments, the first element 101b moves upward or downward in order to horizontally align the protruding portion 101d with the slot 102e. Alternatively or simultaneously, the second element <NUM> is displaced along the arrow C and/or the arrow D in order to horizontally align with the protruding portion 101d of the first element 101b and the outlet 101c or the end portion of the injector 101a. In some embodiments, the second element <NUM> is moved upward, downward, forward or backward in order to horizontally align the slot 102e with the protruding portion 101d and horizontally align the groove <NUM> with the outlet 101c or the end portion of the injector 101a.

In some embodiments, a protruding portion <NUM> of a third element <NUM> is aligned with the slot 102e of the second element <NUM>. In some embodiments, the process of aligning the protruding portion <NUM> of the third element <NUM> with the slot 102e of the second element <NUM> is similar to the process of aligning the protruding portion 101d of the first element 101b with the slot 102e of the second element <NUM>, and repeated description is omitted for a sake of brevity. In some embodiments, the alignment of the protruding portion 101d of the first element 101b with the slot 102e of the second element <NUM> and the alignment of the protruding portion <NUM> of the third element <NUM> with the slot 102e are performed simultaneously.

In operation <NUM>, referring to <FIG> and <FIG>, the second element <NUM> is displaced toward the injection unit <NUM> to slide the protruding portion 101d of the first element 101b along the slot 102e of the second element <NUM>. In operation <NUM>, the outlet 101c is slide into the groove <NUM>.

In some embodiments, after the horizontal alignment, the second element <NUM> is moved towards the injection unit <NUM> along an arrow E as shown in <FIG>. Alternatively, after the horizontal alignment, the injection unit <NUM> is moved towards the second element <NUM> along an arrow L as shown in <FIG>. In some embodiments, the molding device <NUM> is moved towards the second element <NUM> and the injection unit <NUM> after the horizontal alignment of the second element <NUM> and the injection unit <NUM>. In other words, the molding device <NUM> is movable while the injection unit <NUM> and the second element <NUM> are fixed relative to the molding device <NUM>.

<FIG> is a schematic cross-sectional view of the first injection molding system <NUM> of <FIG>. In some embodiments, the protruding portion 101d of the first element 101b slides along the slot 102e, and the outlet 101c or the end portion of the injector 101a slides along the groove <NUM>. In some embodiments, the protruding portion <NUM> of the third element <NUM> slides along the slot 102e. As shown in <FIG>, the protrusion 102f is disposed opposite to the protruding portion 101d of the first element 101b. In some embodiments, the protruding portion 101d of the first element 101b and the protruding portion <NUM> of the third element <NUM> are disposed between a first portion 102x and a second portion 102y of the protrusion 102f.

In some embodiments, in operation <NUM> and operation <NUM>, the first element 101b, the third element <NUM> and the injector 101a are not in contact with the second element <NUM>. In some embodiments, the outlet 101c or the end portion of the injector 101a is surrounded by the groove <NUM> and does not in contact with a step <NUM> within the groove <NUM>. In some embodiments, a first distance D1 between a bottom surface of the protruding portion 101d and the second element <NUM> is substantially greater than a second distance D2 between the outlet 101c and a bottom surface of the groove <NUM>.

In operation <NUM>, the injection unit <NUM> and the supporting device <NUM> are displaced to dispose over the molding device <NUM>. In some embodiments, referring to <FIG>, after the alignment of the injector 101a with the opening <NUM> and the injector 101a, the first element 101b moves towards the molding device <NUM> along an arrow F as shown in <FIG>. In some embodiments, the molding device <NUM> is moved until the supporting device <NUM> overlaps the molding device <NUM> and the injector 101a vertically aligns with a feeding port 102j of the molding device <NUM>. In some embodiments, the molding device <NUM> is moved by rotating the carrier (not shown) carrying the molding device <NUM>.

In operation <NUM>, referring to <FIG>, the outlet 101c is extended toward the molding device <NUM> to engaging the outlet 101c with the opening <NUM>.

In some embodiments, after the alignment of the injector 101a with the opening <NUM>, the injector 101a and the first element 101b move towards the molding device <NUM> along an arrow F as shown in <FIG>, until the outlet 101c of the injector 101a contacts the second element <NUM>. In some embodiments, the outlet 101c is engaged with the opening <NUM> and in contact with the step <NUM>. In some embodiments, the injector 101a and the first element 101b are moved consistently. When the outlet 101c of the injector 101a contacts the second element <NUM>, the entire first element 101b is still not in contact with the second element <NUM>, as shown in <FIG>. In some embodiments, the third element <NUM> (not shown in <FIG>) and the first element 101b are moved consistently in operation <NUM>. In some embodiments, a contact of the second element <NUM> and the outlet 101c is sensed by a second sensor <NUM> disposed within the groove <NUM>. In some embodiments, the contact of the second element <NUM> and the outlet 101c is sensed continuously.

In operation <NUM>, referring to <FIG>, the first element 101b is displaced away from the second element <NUM> while the first element 101b is received by the second element <NUM>. In some embodiments, the protruding portion 101d of the first element 101b is moved to abut against the protrusion 102f of the second element <NUM> while the protruding portion 101d of the first element 101b is received by the slot 102e of the second element <NUM>.

In some embodiments, after the contact of the outlet 101c with the second element <NUM>, the first element 101b moves away from the second element <NUM> along an arrow G as shown in <FIG>, until the protruding portion 101d of the first element 101b contacts the protrusion 102f of the second element <NUM>. In some embodiments, the injector 101a remains stationary when the first element 101b is moving upward as shown in <FIG>. As a result, the first element 101b is engaged with the second element <NUM>. In some embodiments, a contact of the second element <NUM> and the first element 101b is sensed by a first sensor <NUM> disposed on the protrusion 102f and within the slot 102e. In some embodiments, the contact of the second element <NUM> and the first element 101b is sensed by the first sensor <NUM>. In some embodiments, the contact of the protrusion 102f and the protruding portion 101d of the first element 101b is sensed by the first sensor <NUM>. In some embodiments, the contact of the second element <NUM> and the first element 101b is sensed continuously.

In some embodiments, the third element <NUM> (not shown in <FIG>, shown in <FIG>) and the first element 101b are moved consistently in operation <NUM>. In some embodiments, the protruding portion <NUM> (not shown in <FIG>, shown in <FIG>) of the third element <NUM> is moved to abut against the protrusion 102f of the second element <NUM> while the protruding portion <NUM> of the third element <NUM> is received by the slot 102e of the second element <NUM>. In some embodiments, the contact of the protruding portion <NUM> of the third element <NUM> and the protrusion 102f of the second element <NUM> is sensed by the first sensor <NUM>.

In operation <NUM>, referring to <FIG>, a flowable mixture <NUM> is injected into a mold cavity 102i of the molding device <NUM>.

In some embodiments, after the contact of the protruding portion 101d with the protrusion 102f, the flowable mixture <NUM> is injected into the mold cavity 102i as shown in <FIG>. The flowable mixture <NUM> is discharged from the outlet 101c of the injector 101a into the mold cavity 102i through the opening <NUM> and the feeding port 102j of the molding device <NUM>. In some embodiments, the flowable mixture <NUM> is supplied by the flowable mixture supplying unit <NUM> connected to the injector 101a. In some embodiments, a composition of the flowable mixture <NUM> is similar to the flowable mixture prepared by the supplying unit <NUM> as discussed above, and repeated description is omitted for a sake of brevity.

In some embodiments, during the injection of the flowable mixture <NUM>, the outlet 101c is engaged with the opening <NUM> and in contact with the step <NUM>, and the protruding portion 101d of the first element 101b is abutted against the protrusion 102f of the second element <NUM>. During the injection of the flowable mixture <NUM> into the mold cavity 102i by the injector 101a, an injection force I is generated towards the second element <NUM> and/or the molding device <NUM>. In some embodiments, the injection force I acts on the second element <NUM> and/or the molding device <NUM> to push the second element <NUM> and/or the molding device <NUM> away from the injection unit <NUM>, and as a result a counter force C acting on the protruding portion 101d by the protrusion 102f is generated. The protruding portion 101d abuts against the protrusion 102f during the injection of the flowable mixture <NUM>. Therefore, an engagement of the first element 101b and the second element <NUM> as well as an engagement of the outlet 101c and the feeding port 102j are secured. The flowable mixture <NUM> flowing out of the mold cavity 102i can be minimized or even prevented.

In operation <NUM>, referring to <FIG>, the first element 101b is displaced towards the second element <NUM> after the injection of the flowable mixture <NUM>. In some embodiments, the protruding portion 101d of the first element 101b is disengaged from the protrusion 102f of the second element <NUM> after the injection of the flowable mixture <NUM> while the protruding portion 101d of the first element 101b is received by the slot 102e of the second element <NUM>.

In some embodiments, after the injection of the flowable mixture <NUM>, the first element 101b is displaced towards the second element <NUM> along an arrow H as shown in <FIG>, until the first element 101b is disengaged from the second element <NUM>. In some embodiments, the protruding portion 101d is moved away from the protrusion 102f. In some embodiments, the first element 101b is moved toward the molding device <NUM> to disengaged from the protrusion 102f. In some embodiments, the injector 101a remains stationary when the first element 101b is moving downward as shown in <FIG>. In some embodiments, a separation of the protrusion 102f and the protruding portion 101d of the first element 101b is sensed by the first sensor <NUM>.

In some embodiments, the third element <NUM> (not shown in <FIG>, shown in <FIG>) and the first element 101b are moved consistently in operation <NUM>. In some embodiments, the protruding portion <NUM> (not shown in <FIG>, shown in <FIG>) of the third element <NUM> is displaced towards the second element <NUM> after the injection of the flowable mixture <NUM>. In some embodiments, a separation of the protruding portion <NUM> of the third element <NUM> and the protrusion 102f of the second element <NUM> is sensed by the first sensor <NUM>.

In operation <NUM>, referring to <FIG>, the injector 101a is displaced away from the molding device <NUM>. In some embodiments, the outlet 101c is retracted away from the molding device <NUM> after the injection of the flowable mixture <NUM>.

In some embodiments, after the disengagement of the first element 101b from the second element <NUM>, the injector 101a moves away from the molding device <NUM> along an arrow J as shown in <FIG>, until the outlet 101c of the injector 101a is not in contact with the second element <NUM>. In some embodiments, a separation of the injector 101a and the groove <NUM> is sensed by the second sensor <NUM>. In some embodiments, the injector 101a and the first element 101b move away from the molding device <NUM> along the arrow J. In some embodiments, the injector 101a and the first element 101b are moved consistently. In some embodiments, the injector 101a, the first element 101b and the third element <NUM> are moved consistently.

In operation <NUM>, referring to <FIG> and <FIG>, the second element <NUM> and the molding device <NUM> are displaced away from the injection unit <NUM> or displacing the injection unit <NUM> away from the molding device <NUM>.

In some embodiments, after the disengagement of the first element 101b and the injector 101a from the second element <NUM>, the second element <NUM> and the molding device <NUM> are displaced away from the injection unit <NUM>. Alternatively, after the disengagement of the first element 101b and the injector 101a from the second element <NUM>, the injection unit <NUM> is displaced away from the molding device <NUM>. In some embodiments, the second element <NUM> and the molding device <NUM> are horizontally moved away from the first element 101b and the injector 101a along an arrow K as shown in <FIG>. Alternatively, the first element 101b and the injector 101a are horizontally moved away from the second element <NUM> and the molding device <NUM> along an arrow M as shown in <FIG>. <FIG> illustrates the injection unit <NUM> and the second element <NUM> are away from each other after the displacement of the second element <NUM> away from the injection unit <NUM>.

In operation <NUM>, referring to <FIG>, the molding device <NUM> are displaced away from the second element <NUM> or displacing the second element <NUM> away from the molding device <NUM>.

In some embodiments, after the disengagement of the molding device <NUM> from the second element <NUM>, the molding device <NUM> is displaced away from the second element <NUM>. In some embodiments, the molding device <NUM> is displaced away from the second element <NUM> by rotating a carrier (not shown) holding or disposed under the molding device <NUM>. Alternatively, after the disengagement of the second element <NUM> from the molding device <NUM>, the injection unit <NUM>, the molding device <NUM> and the second element <NUM> are separated from each other. In some embodiments, the molding device <NUM> is horizontally moved away from the second element <NUM>. Alternatively, the second element <NUM> are horizontally moved away from the molding device <NUM>. <FIG> illustrates the second element <NUM> and the molding device <NUM> are away from each other after the displacement of the molding device <NUM> away from the second element <NUM>.

<FIG> illustrates a schematic perspective view of a second injection molding system <NUM> according to an embodiment of the present disclosure. In some embodiments, referring to <FIG>, the second injection molding system <NUM> includes an injection unit <NUM>, a molding device <NUM> and a supporting device <NUM> disposed between the injection unit <NUM> and the molding device <NUM>. In some embodiments, the second injection molding system <NUM> further includes a flowable mixture supplying unit <NUM> communicable with the injection unit <NUM>. In some embodiments, the flowable mixture supplying unit <NUM> is configured to produce and supply a flowable mixture to the injection unit <NUM>. In some embodiments, the flowable mixture includes a polymeric material such as ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethanes (TPU), thermoplastic polyester elastomer (TPEE) or the like. In some embodiments, the flowable mixture includes a recyclable material. In some embodiments, the flowable mixture further includes a blowing agent.

In some embodiments, the flowable mixture supplying unit <NUM> of the second injection molding system <NUM> includes an extruder (not shown) for converting the polymeric material into the molten state and a mixer (not shown) for mixing the blowing agent into the polymeric material. The polymeric material is flowable from the extruder into the mixer.

In some embodiments, the injection unit <NUM> includes several injectors 101a disposed between a first element 101b and a third element <NUM> of a supporting device <NUM>. In some embodiments, the supporting device <NUM> surrounds the injectors 101a. In some embodiments, each of the injectors 101a is configured to receive the flowable mixture from the flowable mixture supplying unit <NUM> and discharge the flowable mixture from its outlet 101c. In some embodiments, each of the injectors 101a is communicable with the mixer or the flowable mixture supplying unit <NUM>. In some embodiments, the flowable mixture is discharged from the injector 101a into the molding device <NUM>. Each of the injectors 101a is engageable with a second element <NUM> of the supporting device <NUM>. In some embodiments, the injectors 101a are all engaged with the second element <NUM>. In some embodiments, each of the injectors 101a is vertically extendable/retractable in a first direction as shown by an arrow A. In some embodiments, the injectors 101a are extendable/retractable independent from each other. In some embodiments, each of the injectors 101a is extendable/retractable by a hydraulic mechanism 101e. In some embodiments, the movement of each injectors 101a is actuated and controlled by one hydraulic mechanism 101e.

In some embodiments, the supporting device <NUM> is configured to facilitate an engagement of the injection unit <NUM> and the molding device <NUM>. In some embodiments, the supporting device <NUM> include the first element 101b, the third element <NUM> disposed adjacent to the injectors 101a, and the second element <NUM> dispose on the molding device <NUM>. In some embodiments, the first element 101b and the third element <NUM> are engageable with the second element <NUM>. The first element 101b and the third element <NUM> are extendable toward the molding device <NUM> and retractable from the molding device <NUM> respectively. In some embodiments, each of the first element 101b and the third element <NUM> is vertically extendable/retractable in a way as shown by a second direction as shown by an arrow B. In some embodiments, each of the first element 101b and the third element <NUM> is extendable/retractable along a rail 101f by a motor (not shown) or the like. In some embodiments, each of the first element 101b and the third element <NUM> is moved along the rail 101f, and the movement of each of the first element 101b and the third element <NUM> is actuated and controlled by one motor. In some embodiments, the first direction and the second direction are in parallel.

In some embodiments, the injector 101a, the first element 101b and the third element <NUM> are extendable/retractable independent from each other. The injector 101a, the first element 101b and the third element <NUM> can be displaced relative to each other. In some embodiments, the injector 101a, the first element 101b and the third element <NUM> can be displaced separately or consistently. In some embodiments, all injectors 101a are moved consistently with each other, and the first element 101b and the third element <NUM> are moved consistently with each other. In some embodiments, each of the first element 101b and the third element <NUM> is in a T shape. In some embodiments, the first element 101b includes a protruding portion 101d engageable with the second element <NUM>, and the third element <NUM> includes a protruding portion <NUM> engageable with the second element <NUM>.

In some embodiments, the injection unit <NUM> is disposed above the molding device <NUM>. In some embodiments, the injector 101a, the first element 101b and the third element <NUM> are disposed above the molding device <NUM>. In some embodiments, the molding device <NUM> is configured to receive the flowable mixture discharged from the injectors 101a through the outlets 101c.

In some embodiments, the molding device <NUM> includes a first mold 102c and a second mold 102d engageable with the first mold 102c. In some embodiments, the first mold 102c is an upper mold, and the second mold 102d is a lower mold. In some embodiments, the second element <NUM> is engageable with the first mold 102c. In some embodiments, the molding device <NUM> is disposed on a carrier (not shown) and may be moved together with the carrier. In some embodiments, a plurality of molding devices <NUM> are disposed on the carrier, and the molding devices are arranged in a line, a row, a column, an arc, a curve or any other suitable arrangements. In some embodiments, the carrier is rotatable.

<FIG> illustrates a schematic perspective view of the second element <NUM>, and <FIG> illustrates a schematic top view of the second element <NUM>. In some embodiments, referring to <FIG>, the supporting device <NUM> includes a second element <NUM> engageable with the first element 101b and the third element <NUM>. In some embodiments, the second element <NUM> is disposed on the molding device <NUM>. In some embodiments, the second element <NUM> includes a slot 102e defined by a protrusion 102f and a slot 102o defined by a protrusion 102p.

In some embodiments, the slots 102e, 102o and the protrusions 102f, 102p are laterally elongated. The slot 102e is configured to receive the protruding portion 101d of the first element 101b of the supporting device <NUM>. The slot 102o is configured to receive the protruding portion 101f of the third element <NUM> of the supporting device <NUM>. In some embodiments, the protruding portion 101d of the first element 101b is slidable within and along the slot 102e of the second element <NUM>, and the protruding portion 101f of the third element <NUM> is slidable within and along the slot 102o of the second element <NUM>. In some embodiments, each of a length L1 of the slot 102e and a length L2 of the slot 102o equals to a width W1 of the second element <NUM>. In some embodiments, a height H1 of the slot 102e of the second element <NUM> is greater than a thickness T1 of the protruding portion 101d of the first element 101b, and a height H2 of the slot 102o of the second element <NUM> is greater than a thickness T2 of the protruding portion <NUM> of the third element <NUM>. In some embodiments, each of the protruding portion 101d of the first element 101b and the protruding portion <NUM> of the third element <NUM> is in a T-shape and configured to receive by the slot 102e and the slot 102o respectively.

In some embodiments, the molding device <NUM> includes a groove <NUM> configured to receive the outlet 101e. In some embodiments, the groove <NUM> is disposed on the second element <NUM> and laterally elongated along the second element <NUM>. In some embodiments, the groove <NUM> is in parallel to the protrusion 102f and the protrusion 102p. The groove <NUM> is configured to receive the outlets 101c or an end portions of the injectors 101a of the injection unit <NUM>. The outlets 101c or the end portions of the injectors 101a are slidable within and along the groove <NUM>. In some embodiments, an opening <NUM> is disposed within the groove <NUM>. In some embodiments, the opening <NUM> extends through the second element <NUM>. The outlets 101c or the end portions of the injectors 101a are receivable by the opening <NUM>. The outlets 101c or the end portions of the injectors 101a are movable within the opening <NUM>. In some embodiments, a width W3 of the opening <NUM> is substantially greater than a total widths W2 of the outlets 101c of the injector 101a. In some embodiments, all of the outlets 101c of the injectors 101a are receivable by the opening <NUM>.

In some embodiments, a first sensor <NUM> is disposed within the slot 102e and configured to sense a contact of the protruding portion 101d and the slot 102e, and a third sensor 102q is disposed within the slot 102o and configured to sense a contact of the protruding portion <NUM> and the slot 102o. In some embodiments, the first sensor <NUM> is disposed at the middle end of the slot 102e, and the third sensor 102q is disposed at the middle end of the slot 102o. The first sensor <NUM> and the third sensor 102q are not limited to any particular type, as long as it can sense the pressure and provide pressure information.

In some embodiments, a plurality of first sensors <NUM> are disposed within the slots 102e, and the first sensors <NUM> are configured to sense a position and the contact of the protruding portion 101d and the slot 102e. In some embodiments, a plurality of third sensors 102q are disposed within the slots 102o, and the third sensors 102q are configured to sense a position and the contact of the protruding portion <NUM> and the slot 102o. The number and location of the plurality of third sensors 102q are not particularly limited; for example, they can be arranged at anywhere of the protrusion 102p and within the slot 102o; however, the present invention is not limited thereto.

In some embodiments, a step <NUM> is formed within the groove <NUM> and adjacent to the opening <NUM>. In some embodiments, a second sensor <NUM> is disposed within the groove <NUM> and configured to sense a contact of the outlets 101c and the groove <NUM>.

In some embodiments, a second sensor <NUM> is disposed within the opening <NUM>. The second sensor <NUM> is not limited to any particular type, as long as it can sense the pressure and provide pressure information. In some embodiments, a plurality of second sensor <NUM> are disposed within the opening <NUM>, and the second sensor <NUM> are configured to sense a position and the contact of the outlets 101c and the molding device <NUM>. The number and location of the plurality of second sensors <NUM> are not particularly limited; for example, they can be arranged at anywhere of the opening <NUM>; however, the present invention is not limited thereto.

In some embodiments, the molding device <NUM> can be in an open state and a closed state. The first mold 102c is engaged with the second mold 102d when the molding device <NUM> is in the closed state. <FIG> illustrates a schematic perspective view of the molding device <NUM> in a closed state, and <FIG> illustrates a schematic cross-sectional view of the molding device <NUM> in the closed state. In some embodiments, a mold cavity 102i is defined by the first mold 102c and the second mold 102d when the molding device <NUM> is in the closed state. In some embodiments, the first mold 102c and the second mold 102d define more than one mold cavities 102i. In some embodiments, the mold cavities 102i are isolated from each other. In some embodiments, the mold cavity 102i is configured to receive the flowable mixture from the injectors 101a through the opening <NUM> of the second element <NUM> and the feeding ports 102j. The mold cavity 102i is accessible only through a feeding port 102j when the molding device <NUM> is in the closed state. The mold cavity 102i is accessible through a gap (not shown) between the first mold 102c and the second mold 102d when the molding device <NUM> is in the open state. In some embodiments, the molding device <NUM> includes the feeding port 102j communicable with the mold cavity <NUM>. In some embodiments, the feeding port 102j is disposed at and penetrates through the first mold 102c. In some embodiments, the molding device <NUM> includes several feeding ports 102j as shown in <FIG>. The feeding ports 102j correspond to the mold cavities 102i respectively. In some embodiments, the opening <NUM> is aligned with the feeding ports 102j when the second element <NUM> is disposed over the molding device <NUM>, so that the flowable mixture can flow from the injectos 101a into the mold cavity 102i through the opening <NUM> and the feeding ports 102j. In some embodiments, the opening <NUM> is disposed above all of the feeding ports 102j. In some embodiments, the opening <NUM> is overlapped with the feeding ports 102j when the second element <NUM> is disposed over the molding device <NUM> from a top view.

In the present disclosure, a second injection molding method <NUM> is also disclosed. The second injection molding method <NUM> includes a number of operations, and the description and illustrations are not deemed as a limitation of the sequence of the operations. <FIG> is an embodiment of the second injection molding method <NUM>. In some embodiments, the second injection molding method <NUM> includes a number of operations (<NUM> to <NUM>). <FIG> are schematic cross-sectional views of various stages of the second injection molding method in accordance with some embodiments of the present disclosure. In some embodiments, the second injection molding method <NUM> is implemented by the second injection molding system <NUM> as illustrated in <FIG> and discussed above.

In operation <NUM>, referring to <FIG>, a second injection molding system <NUM> including an injection unit <NUM>, a molding device <NUM> and a supporting device <NUM> is provided. In some embodiments, the second injection molding system <NUM> includes the injection unit <NUM>, the molding device <NUM> and the supporting device <NUM> as discussed above. The molding device <NUM> is in the closed state. The opening <NUM> of the second element <NUM> is aligned with several feeding ports 102j of the molding device <NUM>, so that the mold cavity 102i is accessible through the opening <NUM> and the feeding ports 102j.

In operation <NUM>, a protruding portion 101d of a first element 101b of the supporting device <NUM> is aligned with a first slot 102e of the second element <NUM> of the supporting device <NUM>. In operation <NUM>, a protruding portion <NUM> of a third element <NUM> of the supporting device is aligned with a second slot 102e of the second element <NUM>. In operation <NUM>, a plurality of outlets 101c are aligned with a groove <NUM> of the second element <NUM> configured to receive the outlets 101c. In some embodiments, the alignment of the protruding portion 101d of the first element 101b with the first slot 102e of the second element <NUM>, the alignment of the protruding portion <NUM> of the third element <NUM> with the second slot 102e of the second element <NUM>, and the alignment of the outlets 101c with the groove <NUM> are performed simultaneously.

In some embodiments, the injectors 101a are vertically displaced along the arrow A in order to horizontally align with the groove <NUM>, and the first element 101b and the third element <NUM> are vertically displaced along the arrow B in order to horizontally align with the first slot 102e and the second slot 102e respectively as shown in <FIG>. In some embodiments, the injectors 101a move upward or downward in order to horizontally align with the groove <NUM>. In some embodiments, the first element 101b and the third element <NUM> move upward or downward in order to horizontally align with the first slot 102e and the second slot 102e respectively. Alternatively or simultaneously, the molding device <NUM> is displaced along the arrow C and/or the arrow D in order to horizontally align with the protruding portion 101d of the first element 101b, the protruding portion <NUM> of the third element <NUM>, and the outlets 101c or the end portions of the injectors 101a. In some embodiments, the molding device <NUM> is moved upward, downward, forward and/or backward in order to horizontally align the first slot 102e with the protruding portion 101d, horizontally align the second slot 102e with the protruding portion <NUM>, and horizontally align the groove <NUM> with the outlets 101c or the end portions of the injectors 101a.

In operation <NUM>, referring to <FIG> and <FIG>, the injection unit <NUM> is displaced to slide the protruding portion 101d of the first element 101b along the first slot 102e of the second element <NUM> and the protruding portion <NUM> of the third element <NUM> along the second slot 102e of the second element <NUM>. In operation <NUM>, the outlets 101c are slide into the groove <NUM>.

In some embodiments, after the horizontal alignment, the second element <NUM> is moved towards the injection unit <NUM> along an arrow E as shown in <FIG>. Alternatively, after the horizontal alignment, the injection unit <NUM> is moved towards the second element <NUM> along an arrow L as shown in <FIG>. <FIG> is a schematic cross-sectional view of the second injection molding system <NUM> of <FIG>. In some embodiments, the first element 101b slides along the first slot 102e, the third element <NUM> slides along the second slot 102e, and the outlets 101c or the end portions of the injectors 101a slide along the groove <NUM>. In some embodiments, the second element <NUM> is moved until the first element 101b is disposed within the first slot 102e, the third element <NUM> is disposed within the second slot 102e, and the outlets 101c or the end portions of the injectors 101a are vertically aligned with the opening <NUM>. As shown in <FIG>, the protrusion 102f is disposed opposite to the protruding portion 101d of the first element 101b, and the protrusion 102p is disposed opposite to the protruding portion <NUM> of the third element <NUM>. The first element 101b, the third element <NUM> and the injectors 101a are not in contact with the second element <NUM>. In some embodiments, the outlets 101c of the injectors 101a are align with the opening <NUM> respectively. In some embodiments, a distance D3 between a bottom surface of the protruding portion <NUM> and the second element <NUM> is substantially greater than a distance D4 between the end of the outlet 101c and a top surface of the molding device <NUM>.

In operation <NUM>, the molding device <NUM> is displaced toward the injection unit <NUM> and the supporting device <NUM> to dispose under the supporting device <NUM>. In some embodiments, referring to <FIG>, after the alignment of the injector 101a with the opening <NUM>, the injector 101a and the first element 101b move towards the molding device <NUM> along an arrow F as shown in <FIG>. In some embodiments, the molding device <NUM> is moved until the supporting device <NUM> covers the molding device <NUM> and the injectors 101a are vertically align with a feeding ports 102j of the molding device <NUM>. In some embodiments, the molding device <NUM> is moved by moving, such as rotating, the carrier (not shown) disposed under the molding device <NUM>. In some embodiments, the molding device <NUM> is moved until the outlets 101c or the end portions of the injectors 101a are vertically aligned with the feeding ports 102j of the molding device <NUM>.

In operation <NUM>, referring to <FIG>, the outlets 101c are extended toward the molding device <NUM> to engaging the outlets 101c with the molding device <NUM>.

In some embodiments, after the alignment of the injectors 101a with the opening <NUM>, the injectors 101a, the first element 101b and the third element <NUM> move towards the molding device <NUM> along an arrow F as shown in <FIG>, until the outlets 101c of the injectors 101a contacts the second element <NUM>. In some embodiments, the outlets 101c are in contact with the first mold 102c. In some embodiments, the injectors 101a, the first element 101b and the third element <NUM> are moved consistently. When the outlets 101c of the injector 101a contacts the first mold 102c, the entire first element 101b and the entire third element <NUM> are still not in contact with the second element <NUM>, as shown in <FIG>. In some embodiments, a contact of the molding device <NUM> and the outlets 101c is sensed by a second sensor <NUM> disposed within the groove <NUM>. In some embodiments, a contact of the molding device <NUM> and the outlets 102c is sensed continuously.

In operation <NUM>, referring to <FIG>, the first element 101b and the third element <NUM> are displaced away from the second element <NUM> while the first element 101b and the third element <NUM> are received by the second element <NUM>. In some embodiments, the protruding portion 101d of the first element 101b is moved to abut against a protrusion 102f of the second element <NUM> while the protruding portion 101d of the first element 101b is received by the first slot 102e of the second element <NUM>, and the protruding portion <NUM> of the third element <NUM> is moved to abut against the protrusion 102p of the second element <NUM> while the protruding portion <NUM> of the third element <NUM> is received by the second slot 102e of the second element <NUM>.

In some embodiments, after the contact of the outlets 101c with the molding device <NUM>, the first element 101b and the third element <NUM> move away from the second element <NUM> along an arrow G as shown in <FIG>, until the protruding portion 101d of the first element 101b and the protruding portion <NUM> of the third element <NUM> contacts the protrusion 102f and the protrusion 102p of the second element <NUM> respectively. In some embodiments, the injectors 101a remain stationary when the first element 101b and third element <NUM> are moving upward as shown in <FIG>. As a result, the first element 101b and third element <NUM> are engaged with the second element <NUM>.

In some embodiments, the contact of the second element <NUM> and the first element 101b is sensed by the first sensor <NUM>. In some embodiments, the contact of the protrusion 102f and the protruding portion 101d of the first element 101b is sensed by the first sensor <NUM>. In some embodiments, a contact of the second element <NUM> and the first element 101b is sensed continuously. In some embodiments, a contact of the second element <NUM> and the third element <NUM> is sensed by a third sensor 102q disposed on the protrusion 102p and within the second slot 102e. In some embodiments, the contact of the second element <NUM> and the third element <NUM> is sensed by the third sensor 102q. In some embodiments, the contact of the protrusion 102p and the protruding portion <NUM> of the third element <NUM> is sensed by the third sensor 102q. In some embodiments, a contact of the second element <NUM> and the third element <NUM> is sensed continuously.

In some embodiments, after the contact of the protruding portion 101d with the protrusion 102f and the contact of the protruding portion <NUM> with the protrusion 102p, the flowable mixture <NUM> is injected into the mold cavity102i as shown in <FIG>. The flowable mixture <NUM> is discharged from the outlets 101c of the injectors 101a into the mold cavity 102i through the opening <NUM> and the feeding ports 102j. In some embodiments, the flowable mixture <NUM> is supplied by the flowable mixture supplying unit <NUM> connected to the injectors 101a. In some embodiments, a composition of the flowable mixture <NUM> is similar to the flowable mixture prepared by the supplying unit <NUM> as discussed above, and repeated description is omitted for a sake of brevity.

In some embodiments, during the injection of the flowable mixture <NUM>, the outlets 101c are engaged with the molding device <NUM>, the protruding portion 101d of the first element 101b is abutted against the protrusion 102f of the second element <NUM>, and the protruding portion <NUM> of the third element <NUM> is abutted against the protrusion 102p of the fourth element 102o. During the injection of the flowable mixture <NUM> into the mold cavity 102i by the injectors 101a, an injection force I is generated towards the molding device <NUM>. In some embodiments, the injection force I acts on the molding device <NUM> to push the molding device <NUM> away from the injection unit <NUM>, and as a result a counter force C acting on the protruding portion 101d by the protrusion 102f is generated. The protruding portion 101d abuts against the protrusion 102f and the protruding portion <NUM> abuts against the protrusion 102p during the injection of the flowable mixture <NUM>. Therefore, an engagement of the first element 101b and the second element <NUM>, an engagement of the third element <NUM> and the second element <NUM> as well as an engagement of the outlet 101c and the feeding port 102j are secured. The flowable mixture <NUM> flowing out of the mold cavity 102i can be minimized or even prevented.

In operation <NUM>, referring to <FIG>, the first element 101b and the third element <NUM> are displaced towards the second element <NUM> after the injection of the flowable mixture <NUM>. In some embodiments, the protruding portion 101d of the first element 101b is disengaged from the protrusion 102f of the second element <NUM> and the protruding portion <NUM> of the third element <NUM> is disengaged from the protrusion 102p of the second element <NUM> after the injection of the flowable mixture <NUM> while the protruding portion 101d of the first element 101b is received by the first slot 102e of the second element <NUM> and the protruding portion <NUM> of the third element <NUM> is received by the second slot 102e of the second element <NUM>.

In some embodiments, after the injection of the flowable mixture <NUM>, the first element 101b and the third element <NUM> are displaced towards the second element <NUM> along an arrow H as shown in <FIG>, until the first element 101b is disengaged from the second element <NUM>. In some embodiments, the protruding portion 101d is moved away from the protrusion 102f, and the protruding portion <NUM> is moved away from the protrusion 102p. In some embodiments, the first element 101b is moved toward the molding device <NUM> to disengaged from the protrusion 102f, and the third element <NUM> is moved toward the molding device <NUM> to disengaged from the protrusion 102p. In some embodiments, the injectors 101a remain stationary when the first element 101b and the third element <NUM> are moving downward as shown in <FIG>. In some embodiments, a separation of the protrusion 102f and the protruding portion 101d of the first element 101b is sensed by the first sensor <NUM>, and a separation of the protrusion 102p and the protruding portion <NUM> of the third element <NUM> is sensed by the third sensor 102q.

In operation <NUM>, referring to <FIG>, the injectors 101a are displaced away from the molding device <NUM>. In some embodiments, the outlets 101c are retracted away from the molding device <NUM> after the injection of the flowable mixture <NUM>.

In some embodiments, after the disengagement of the first element 101b and the third element <NUM> from the second element <NUM>, the injectors 101a move away from the molding device <NUM> along an arrow J as shown in <FIG>, until the outlets 101c of the injectors 101a are not in contact with the molding device <NUM>. In some embodiments, a separation of the injectors 101a and the molding device <NUM> is sensed by the second sensor <NUM>. In some embodiments, the injectors 101a, the first element 101b and the third element <NUM> move away from the molding device <NUM> along the arrow J. In some embodiments, the injectors 101a, the first element 101b and the third element <NUM> are moved consistently.

In operation <NUM>, referring to <FIG> and <FIG>, the molding device <NUM> is displaced away from the injection unit <NUM> or displacing the injection unit <NUM> away from the molding device <NUM>.

In some embodiments, after the disengagement of the injectors 101a, the first element 101b and the third element <NUM> from the second element <NUM>, the molding device <NUM> is displaced away from the injection unit <NUM>. Alternatively, after the disengagement of the injectors 101a, the first element 101b and the third element <NUM> from the second element <NUM>, the injection unit <NUM> is displaced away from the second element <NUM>. In some embodiments, the molding device <NUM> is horizontally moved away from the injectors 101a, the first element 101b and the third element <NUM> along an arrow K as shown in <FIG>. Alternatively, the injectors 101a, the first element 101b and the third element <NUM> are horizontally moved away from the second element <NUM> and the molding device <NUM> along an arrow M as shown in <FIG>. <FIG> illustrates the injection unit <NUM> and the second element <NUM> are away from each other after the displacement of the second element <NUM> away from the injection unit <NUM>.

In some embodiments, after the disengagement of the molding device <NUM> from the second element <NUM>, the molding device <NUM> is displaced away from the second element <NUM>. In some embodiments, the molding device <NUM> is horizontally moved away from the second element <NUM> along an arrow K as shown in <FIG>. In some embodiments, the molding device <NUM> is displaced away from the second element <NUM> by rotating a carrier (not shown) disposed under the molding device <NUM>, and another molding device (not shown) may disposed under the second element <NUM>. Alternatively, after the disengagement of the second element <NUM> from the molding device <NUM>, the injection unit <NUM>, the molding device <NUM> and the second element <NUM> are separated from each other. In some embodiments, the molding device <NUM> is horizontally moved away from the second element <NUM>. Alternatively, the second element <NUM> are horizontally moved away from the molding device <NUM>. <FIG> illustrates the second element <NUM> and the molding device <NUM> are away from each other after the displacement of the molding device <NUM> away from the second element <NUM>.

In the present disclosure, a third injection molding method <NUM> is also disclosed. The third injection molding method <NUM> includes a number of operations, and the description and illustrations are not deemed as a limitation of the sequence of the operations. <FIG> is an embodiment of the third injection molding method <NUM>. In some embodiments, the third injection molding method <NUM> includes a number of operations (<NUM> to <NUM>). In some embodiments, the third injection molding method <NUM> is implemented by the first injection molding system <NUM> as illustrated in <FIG> or the second injection molding system <NUM> as illustrated in <FIG> and discussed above.

In operation <NUM>, an injection molding system is provided, wherein the injection molding system includes an injection unit and a molding device, the injection unit includes an outlet configured to discharge a flowable mixture, and the molding device is configured to receive the flowable mixture from the outlet and includes a mold cavity and a feeding port communicable with the mold cavity and correspondingly engageable with the outlet.

In operation <NUM>, a supporting device configured to facilitate an engagement of the injection unit and the molding device is provided, wherein the supporting device includes a first element connected to the injection unit and a second element disposed on the molding device.

In operation <NUM>, a protruding portion of the first element is aligned with a slot of the second element.

In operation <NUM>, the injection unit is displaced to slide the protruding portion of the first element along the slot of the second element.

In operation <NUM>, the outlet is displaced in an opening of the second element to engage with the feeding port when the protruding portion of the first element is engaged with the slot of the second element.

In operation <NUM>, the flowable mixture is injected into the mold cavity.

An aspect of this disclosure relates to an injection molding system. The injection molding system includes a supplying unit configured to supply a flowable mixture of a polymeric material and a blowing agent; an injection unit communicable with the supplying unit, wherein the injection unit includes an outlet disposed distal from the supplying unit and configured to discharge the flowable mixture; a molding device configured to receive the flowable mixture from the outlet and including a mold cavity and a feeding port communicable with the mold cavity and engageable with the outlet; and a supporting device disposed between the injection unit and the molding device and configured to facilitate an engagement of the injection unit and the molding device. The supporting device includes a first element connected to the injection unit and a second element disposed on the molding device. The second element includes a first slot configured to receive a protruding portion of the first element, the protruding portion of the first element is slidable within and along the first slot 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 includes a protrusion for defining the first slot, and the first slot 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 slot. In some embodiments, the second element further includes a groove configured to receive the outlet, and the groove is laterally elongated along the second element and in parallel to the first slot. In some embodiments, the outlet is slidable within and along the groove. In some embodiments, the second element further includes an opening is disposed within the groove. In some embodiments, a first sensor is disposed within the first slot and configured to sense a contact of the protruding portion and the first slot. In some embodiments, a second sensor is disposed within the groove and configured to sense a contact of the outlet and the groove. In some embodiments, a height of the first slot is greater than a thickness of the protruding portion of the first element. In some embodiments, the supporting device further includes a third element connected to the injection unit, and the first slot is configured to receive the first element and the third element. In some embodiments, the supporting device further includes a third element connected to the injection unit, and the second element further includes a second slot configured to receive the third element.

An aspect of this disclosure relates to an injection molding method. The molding method includes: providing an injection molding system, wherein the injection molding system includes an injection unit and a molding device, the injection unit includes an outlet configured to discharge a flowable mixture, and the molding device is configured to receive the flowable mixture from the outlet and includes a mold cavity and a feeding port communicable with the mold cavity and correspondingly engageable with the outlet; providing a supporting device configured to facilitate an engagement of the injection unit and the molding device, wherein the supporting device includes a first element connected to the injection unit and a second element disposed on the molding device; aligning a protruding portion of the first element with a slot of the second element; displacing the injection unit to slide the protruding portion of the first element along the slot of the second element; displacing the outlet in an opening of the second element to engage the outlet with the feeding port when the protruding portion of the first element is engaged with the slot of the second element; and injecting the flowable mixture into the mold cavity.

In some embodiments, the method further includes aligning the outlet with a groove configured to receive the outlet, the groove is laterally elongated along the second element and in parallel to the slot; and sliding the outlet into the groove. In some embodiments, the alignment of the protruding portion of the first element with the slot of the second element and the alignment of the outlet with the groove are performed simultaneously. In some embodiments, the method further includes extending the outlet toward the molding device to engage the outlet with the feeding port; and retracting the outlet away from the molding device after the injection of the flowable mixture. In some embodiments, the method further includes 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 slot of the second element; and disengaging the protruding portion of the first element from the slot of the second element after the injection of the flowable mixture, wherein the slot is defined by the protrusion. In some embodiments, the first element is moved away from the molding device to abut against the protrusion, and moved toward the molding device to disengage from the protrusion. In some embodiments, the method further includes moving the protruding portion of the first element toward the molding device after the injection of the flowable mixture while the protruding portion of the first element is received by the slot of the second element; wherein the injection unit remains stationary when the supporting device is moving toward the molding device. In some embodiments, during the injection the flowable mixture, the protruding portion of the first element abuts against a protrusion of the second element, and the outlet is communicable with the feeding port.

The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure 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.

Claim 1:
An injection molding system (<NUM>), comprising:
a supplying unit (<NUM>) configured to supply a flowable mixture of a polymeric material and a blowing agent;
an injection unit (<NUM>) communicable with the supplying unit, wherein the injection unit includes an outlet (101c) disposed distal from the supplying unit and configured to discharge the flowable mixture;
a molding device (<NUM>) configured to receive the flowable mixture from the outlet and including:
a mold cavity (102i); and
a feeding port (<NUM>) communicable with the mold cavity and engageable with the outlet; and
a supporting device (<NUM>) disposed between the injection unit and the molding device and configured to facilitate an engagement of the injection unit and the molding device, wherein the supporting device includes a first element (101b) connected to the injection unit and a second element (<NUM>) disposed on the molding device, the second element includes a first slot (102e) configured to receive a protruding portion of the first element,
characterized in that the protruding portion (101d) of the first element is slidable within and along the first slot of the second element.