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 a method of injection molding for forming an article including more than one portion having different physical or functional properties.

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

Foamed polymeric material has many advantages, such as high strength, low weight, impact resistance, thermal insulation, and others. Foamed articles can be made by injection molding or extrusion molding. For example, after the polymeric material is melted and mixed with a blowing agent to form a mixture, a force or pressure is applied to the mixture to inject or extrude the mixture into a cavity of a mold, and the mixture is foamed and cooled in the cavity to form the foamed article.

However, it is necessary to improve the properties of the foamed article made by the injection molding system, such as causing different portions of the foamed article to have different properties. Therefore, there is a need for improvements to structures of the injection-molding system and the method for making foamed articles.

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

According to one embodiment of the present disclosure, an injection molding system is provided. The injection molding system includes a first carrier configured to hold a first mold; a first injector disposed over the first carrier and configured to inject a first polymeric material; a second carrier configured to hold a second mold; a second injector disposed over the second carrier and configured to inject a second polymeric material; and a bridging mechanism disposed between and moveable relative to the first carrier and the second carrier. The bridging mechanism is configured to receive a third mold from the first carrier or the second carrier and convey the third mold between the first carrier and the second carrier.

According to one embodiment of the present disclosure, an injection molding method is provided. The injection molding method includes: providing an injection molding system including a first carrier, a second carrier disposed adjacent to the first carrier, a bridging mechanism between the first carrier and the second carrier, a first injector over the first carrier, a second injector over the second carrier, a first mold held on the first carrier, and a second mold held on the second carrier; engaging a third mold with the first mold to form a first mold cavity; injecting a first polymeric material into the first mold cavity by the first injector; moving the third mold carrying the first polymeric material to the bridging mechanism; conveying the third mold to the second carrier by the bridging mechanism; engaging the third mold with the second mold to form a second mold cavity; injecting a second polymeric material into the second mold cavity by the second injector; and obtaining an article including the first polymeric material and the second polymeric material.

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 the 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.

<FIG> is a schematic perspective view of an injection molding system <NUM> in accordance with some embodiments of the present disclosure, and <FIG> is a schematic top view of the injection molding system <NUM> of <FIG>. The injection molding system <NUM> includes a first carrier <NUM> and a second carrier <NUM> disposed adjacent to the first carrier <NUM>.

In some embodiments, the first carrier <NUM> is rotatable about a first center C1 and along a first direction R1, and the second carrier <NUM> is rotatable about a second center C2 and along a second direction R2. In some embodiments, the first carrier <NUM> and the second carrier <NUM> are in an annular shape. In some embodiments, the first carrier <NUM> and the second carrier <NUM> are turntables. In some embodiments, the first carrier <NUM> is rotatable in a direction same as the second carrier <NUM>. For example, both the first carrier <NUM> and the second carrier <NUM> are rotatable in anti-clockwise direction. In some embodiments, the first carrier <NUM> is rotatable in a direction opposite to the second carrier <NUM>. For example, the first carrier <NUM> is rotatable in anti-clockwise direction, and the second carrier <NUM> is rotatable in clockwise direction, or vice versa. In some embodiments, the first carrier <NUM> and the second carrier <NUM> are operated and controlled automatically. In some embodiments, the first carrier <NUM> and the second carrier <NUM> communicable with each other through any suitable communication protocol such as programmable logic control (PLC) protocol or the like.

In some embodiments, multiple molding stations <NUM> are configured on the first carrier <NUM> and the second carrier <NUM>. Each molding station <NUM> includes a lower mold <NUM> and an upper mold <NUM> disposed above the lower mold <NUM>. In the embodiment of the injection molding system <NUM>, the molding stations <NUM> configured on the first carrier <NUM> are referred as the first molding stations 200a, and the molding stations <NUM> configured on the second carrier <NUM> are referred as the second molding stations 200b.

<FIG> is a schematic cross-sectional view of the first molding station 200a in a closed configuration in accordance with some embodiments of the present disclosure. In <FIG>, the first molding station 200a includes a lower mold <NUM> and a first upper mold 202a. In some embodiments, the first upper mold 202a corresponds to the lower mold <NUM> in some configurations such as dimension, shape or the like. The first upper mold 202a can be placed on and engaged with the lower mold <NUM>. In some embodiments, a first mold cavity 203a is defined by the first upper mold 202a and the lower mold <NUM> when the first molding station 200a is in the closed configuration. Although <FIG> illustrates only one first mold cavity 203a in the closed configuration, it can be understood that any suitable numbers of the first mold cavity 203a can be configured in the closed configuration.

In some embodiments, a first sprue 204a is configured at the first upper mold 202a. The first sprue 204a is configured to extend through the first upper mold 202a, and is communicable with the first mold cavity 203a when the first molding station 200a is in the closed configuration. For simplicity and clarity, only one first sprue 204a is illustrated, however, it can be understood that any suitable numbers of the first sprue 204a can be configured at the first upper mold 202a.

In some embodiments, a removable plate (not shown) can be placed between the first upper mold 202a and the lower mold <NUM> for adjusting a volume of the first mold cavity 203a. For example, the first mold cavity 203a would be reduced if the removable plate is inserted into the first mold cavity 203a and disposed between the first upper mold 202a and the lower mold <NUM>. As such, the volume of the first mold cavity 203a can be adjusted by insertion of the removable plate between the first upper mold 202a and the lower mold <NUM> when the first molding station 200a is closed.

<FIG> is a schematic cross-sectional view of the second molding station 200b in a closed configuration in accordance with some embodiments of the present disclosure. In <FIG>, the second molding station 200b includes the lower mold <NUM> and a second upper mold 202b. In some embodiments, the second upper mold 202b corresponds to the lower mold <NUM> in some configurations such as dimension, shape or the like. The second upper mold 202b can be placed on and engaged with the lower mold <NUM>. In some embodiments, a second mold cavity 203b is defined by the second upper mold 202b and the lower mold <NUM> when the second molding station 200b is in the closed configuration.

In some embodiments, a second sprue 204b is configured at the second upper mold 202b. The second sprue 204b is configured to extend through the second upper mold 202b, and is communicable with the second mold cavity 203b when the second molding station 200b is in the closed configuration. In some embodiments, a removable plate (not shown) can be placed between the second upper mold 202b and the lower mold <NUM> for adjusting a volume of the second mold cavity 203b.

In some embodiments, each of the first carrier <NUM> and the second carrier <NUM> includes multiple holders (not shown) for holding the first upper molds 202a or the second upper molds 202b. In some embodiments, the first upper mold 202a of <FIG> and the second upper mold 202b of <FIG> have different configurations. In some embodiments, the lower molds <NUM> of the first molding stations 200a in <FIG> and the lower molds <NUM> of the second molding stations 200b in <FIG> have the same configurations.

Referring back to <FIG> and <FIG> together , the injection molding system <NUM> further includes a first injector <NUM> adjacent to the first carrier <NUM> and a second injector <NUM> adjacent to the second carrier <NUM>. The first injector <NUM> is disposed over one of the first molding stations 200a and configured to discharge a first polymeric material M1 into the first mold cavity 203a defined by the corresponding lower mold <NUM> and the corresponding first upper mold 202a of the one of the first molding stations 200a. Similarly, the second injector <NUM> is disposed over one of the second molding stations 200b and configured to discharge a second polymeric material M2 into the second mold cavity 203b defined by the corresponding lower mold <NUM> and the corresponding second upper mold 202b of the one of the second molding stations 200b. In some embodiments, the first polymeric material M1 can be flowed from the first injector <NUM> into the first mold cavity 203a through the first sprue 204a, and the second polymeric material M2 can be flowed from the second injector <NUM> into the second mold cavity 203b through the second sprue 204b.

In some embodiments, the first injector <NUM> is coupled to a first mixing unit (not shown) that is configured to mix a polymeric material with a blowing agent to produce the first polymeric material and convey the first polymeric material to the first injector <NUM>. In some embodiments, similarly, the second injector <NUM> is coupled to a second mixing unit (not shown) that is configured to mix a polymeric material with a blowing agent to produce the second polymeric material and convey the second polymeric material to the second injector <NUM>.

In some embodiments, the first injector <NUM> is disposed over the first carrier <NUM>. In some embodiments, the holders (not shown) pass under the first injector <NUM> one by one upon rotation of the first carrier <NUM>. In some embodiments, the first injector <NUM> is fixedly installed over the first carrier <NUM>. The first carrier <NUM> is movable relative to the first injector <NUM>, and the first injector <NUM> is stationary relative to the first carrier <NUM>.

In some embodiments, the second injector <NUM> is disposed over the second carrier <NUM>. In some embodiments, the holders (not shown) pass under the second carrier <NUM> one by one upon rotation of the second carrier <NUM>. In some embodiments, the second injector <NUM> is fixedly installed over the second carrier <NUM>. The second carrier <NUM> is movable relative to the second injector <NUM>, and the second injector <NUM> is stationary relative to the second carrier <NUM>.

In some embodiments, the first polymeric material M1 and the second polymeric material M2 have the same or different physical properties (such as density, hardness, Young's modules, etc.). In some embodiments, the first polymeric material M1 and the second polymeric material M2 include thermoplastic polyurethane (TPU), polyurethane (PU), plastics or any other suitable materials. In some embodiments, the first polymeric material and the second polymeric material are foamable materials.

The injection molding system <NUM> further includes a bridging mechanism <NUM> disposed between the first carrier <NUM> and the second carrier <NUM>. The bridging mechanism <NUM> is rotatable or moveable relative to the first carrier <NUM> and the second carrier <NUM>. The bridging mechanism <NUM> is configured to connect the first carrier <NUM> with the second carrier <NUM> so as to sequentially convey the lower molds <NUM> from the first carrier <NUM> to the second carrier <NUM> or vice versa.

In some embodiments, the bridging mechanism <NUM> is in an annular shape. In some embodiments, the bridging mechanism <NUM> is rotatable about a third center C3 and along a third direction R3. In some embodiments, the bridging mechanism <NUM> is rotatable in clockwise or anti-clockwise. In some embodiments, the bridging mechanism <NUM> is removable and detachable from the injection molding system <NUM>. The bridging mechanism <NUM> is operable independent from the first carrier <NUM> and the second carrier <NUM>. In some embodiments, the first center C1 of the first carrier <NUM>, the third center C3 of the bridging mechanism <NUM> and the second center C2 of the second carrier <NUM> are arranged on a straight line. In other words, the first carrier <NUM> and the second carrier <NUM> are disposed at opposite sides of the bridging mechanism <NUM>.

In the embodiment of the injection molding system <NUM>, the bridging mechanism <NUM> includes two conveying units 103a and 103b. The conveying units 103a and 103b are disposed at opposite sides of the bridging mechanism <NUM>. Each of the conveying units 103a and 103b is configured to convey the lower mold <NUM> from the first carrier <NUM> to the bridging mechanism <NUM> or vice versa, or from the second carrier <NUM> to the bridging mechanism <NUM> or vice versa. In some embodiments, each of the conveying units 103a and 103b is a rail, belt or any other conveying means. In some embodiments, the bridging mechanism <NUM> may include single or more than two conveying units.

The bridging mechanism <NUM> further includes two receiving spaces 103c and 103d. The receiving spaces 103c and 103d are disposed at opposite sides of the bridging mechanism <NUM>. Each of the receiving spaces 103c and 103d is configured to receive and temporarily hold the lower mold <NUM> to be conveyed. In some embodiments, one lower mold <NUM> can be held within one of the receiving spaces 103c and 103d during the rotation of the bridging mechanism <NUM>. In some embodiments, during the rotation of the bridging mechanism <NUM>, the two lower mold <NUM> can be held within the receiving spaces 103c and 103d, respectively. In some embodiments, the receiving space 103c and the conveying unit 103a are positioned in close proximity to each other, either set together or placed adjacent to one another, and the receiving space 103d and the conveying unit 103b are positioned in close proximity to each other.

In some embodiments, the injection molding system <NUM> further includes an additional processing unit (not shown) that is arranged adjacent to the bridging mechanism <NUM>. In some embodiments, the additional processing unit is configured to treat or process the lower mold <NUM> when the lower mold <NUM> is held within the receiving space 103c or 103d. In some embodiments, the additional processing unit is configured to perform various processes such as inserting a color block into the lower mold <NUM>, trimming a runner or other redundant part from an intermediate article inside the lower mold <NUM>, heating or pre-heating the lower mold <NUM> and/or the intermediate article inside the lower mold <NUM>, cleaning the lower mold <NUM>, etc. In some embodiments, the additional processing unit includes an injector, a cutter, a heater, a cleaner and so on.

<FIG> is a flowchart showing an injection molding method <NUM> in accordance with some embodiments of the present disclosure. The injection molding method <NUM> includes the operations S302 through S316, and the description and illustrations are not deemed as a limitation of the sequence of the operations S302 through S316. <FIG> are schematic top or cross-sectional views of various stages of the injection molding method <NUM>. In some embodiments, the operations of the injection molding method <NUM> can be repeated and performed automatically.

In order to illustrate concepts and the injection molding method <NUM> of the present disclosure, various embodiments are provided below. However, the present disclosure is not intended to be limited to specific embodiments. In addition, elements, conditions or parameters illustrated in different embodiments can be combined or modified to form different combinations of embodiments as long as the elements, parameters or conditions used are not in conflict. For ease of illustration, reference numerals with similar or same functions and properties are repeated in different embodiments and figures.

First, in the operation S302 of the injection molding method <NUM>, the injection molding system <NUM> is provided or received, as shown in <FIG>. The injection molding system <NUM> of <FIG> has same configuration as the one shown in <FIG> and <FIG>. For simplicity, only two lower molds <NUM> on the first carrier <NUM> and two lower molds <NUM> on the second carrier <NUM> are shown in <FIG>. However, it would be understood that each of the lower molds <NUM> on the first carrier <NUM> is under the corresponding one of the first upper molds 202a, and each of the lower molds <NUM> on the second carrier <NUM> is under the corresponding one of the second upper molds 202b. Furthermore, it is not intended to limit the number of lower molds <NUM> on the first carrier <NUM> and the second carrier <NUM>.

In some embodiments, the first injector <NUM> is disposed above one of the first molding stations 200a, and the second injector <NUM> is disposed above one of the second molding stations 200b. In some embodiments, all of the first upper molds 202a are fixedly attached to the first carrier <NUM>, and all of the second upper molds 202b are fixedly attached to the second carrier <NUM>.

As shown in <FIG>, the lower molds <NUM> on the first carrier <NUM> are referred to as a first lower mold <NUM>-<NUM> and a second lower mold <NUM>-<NUM>, and the lower molds <NUM> on the second carrier <NUM> are referred to as a third lower mold <NUM>-<NUM> and a fourth lower mold <NUM>-<NUM>. The first injector <NUM> is disposed above the second lower mold <NUM>-<NUM> and the corresponding one of the first upper molds 202a, and the second injector <NUM> is disposed above the fourth lower mold <NUM>-<NUM> and the corresponding one of the second upper molds 202b.

Referring back to <FIG>, in the operation S304 of the injection molding method <NUM>, the lower mold on the first carrier <NUM> under the first injector <NUM> (e.g., the lower mold <NUM>-<NUM> of <FIG>) is engaged with the corresponding one of the first upper molds 202a to form the first mold cavity 203a.

Next, in the operation S306 of the injection molding method <NUM>, the first polymeric material M1 is injected into the first mold cavity by the first injector <NUM>. As shown in <FIG>, the first polymeric material M1 from the first injector <NUM> is injected into the first mold cavity 203a through the first sprue 204a, and the first mold cavity 203a is formed by the lower mold <NUM>-<NUM> under the first injector <NUM> and the corresponding first upper mold 202a. In some embodiments, the first polymeric material M1 includes thermoplastic polyurethane (TPU), polyurethane (PU), plastics or any other suitable materials. In some embodiments, the first polymeric material M1 includes a physical blowing agent such as supercritical fluid. In some embodiments, the physical blowing agent is gaseous nitrogen, carbon dioxide, etc. In some embodiments, the first polymeric material M1 is foamable, non-foamable or slightly foamable.

After the first polymeric material M1 is injected, the first carrier <NUM> and the second carrier <NUM> are rotated in the first direction R1 and the second direction R2, respectively. <FIG> shows the first carrier <NUM> and the second carrier <NUM> after the rotation. In some embodiments, the first carrier <NUM> and the second carrier <NUM> are rotated at a predetermined interval. In some embodiments, the first carrier <NUM> and the second carrier <NUM> are rotated independently or simultaneously. In some embodiments, the first carrier <NUM> and the second carrier <NUM> are rotated in different speed or the same speed. In some embodiments, the first direction R1 and the second direction R2 can be same as or different from each other. As shown in <FIG>, after the rotation, the first lower mold <NUM>-<NUM> and the corresponding one of the first upper molds 202a are disposed adjacent to the first receiving space 103c of the bridging mechanism <NUM>, and the third lower mold <NUM>-<NUM> and the corresponding one of the second upper molds 202b are disposed adjacent to the second receiving space 103d of the bridging mechanism <NUM>. In some embodiments, the first lower mold <NUM>-<NUM> is aligned with the first receiving space 103c, and the third lower mold <NUM>-<NUM> is aligned with the second receiving space 103d.

After the rotation of the first carrier <NUM>, the first lower mold <NUM>-<NUM> is disengaged with the corresponding one of the first upper molds 202a as shown in <FIG>. In an open configuration of <FIG>, no first polymeric material M1 is injected into the first mold cavity 203a of the lower mold <NUM>-<NUM>. Similarly, after the rotation of the second carrier <NUM>, the third lower mold <NUM>-<NUM> is disengaged with the corresponding one of the second upper molds 202b as shown in an open configuration of <FIG>. That is, the first lower mold <NUM>-<NUM> is movable relative to the first carrier <NUM>, and the third lower mold <NUM>-<NUM> is movable relative to the second carrier <NUM>.

After the first lower mold <NUM>-<NUM> and the third lower mold <NUM>-<NUM> are disengaged, the first lower mold <NUM>-<NUM> is moved from the first carrier <NUM> into the first receiving space 103c of the bridging mechanism <NUM> by the first conveying unit 103a, and the third lower mold <NUM>-<NUM> is moved from the second carrier <NUM> into the second receiving space 103d of the bridging mechanism <NUM> by the second conveying unit 103b, as shown in <FIG>.

After the first lower mold <NUM>-<NUM> and the third lower mold <NUM>-<NUM> are moved to the bridging mechanism <NUM>, the bridging mechanism <NUM> is rotated in the third direction R3 to convey the first lower mold <NUM>-<NUM> and the third lower mold <NUM>-<NUM>. In some embodiments, the first carrier <NUM> and the second carrier <NUM> stop rotation temporarily during the rotation of the bridging mechanism <NUM>. In some embodiments, the bridging mechanism <NUM> is rotated in a predetermined angle as shown in <FIG> so that the first lower mold <NUM>-<NUM> is away from the first carrier <NUM> and the third lower mold <NUM>-<NUM> is away from the second carrier <NUM>. After the rotation in the predetermined angle, the first lower mold <NUM>-<NUM> and the third lower mold <NUM>-<NUM> are processed by one or more additional processing units (not shown) configured at or over the bridging mechanism <NUM>.

In some embodiments, the bridging mechanism <NUM> then continues the rotation, so that the first lower mold <NUM>-<NUM> is disposed adjacent to the second carrier <NUM> and the third lower mold <NUM>-<NUM> is disposed adjacent to the first carrier <NUM> as shown in <FIG>. In some embodiments, the bridging mechanism <NUM> is rotated directly from a position as shown in <FIG> to a position as shown in <FIG>, without stopping at a position as shown in <FIG>. As shown in <FIG>, after the rotation of the bridging mechanism <NUM>, the first lower mold <NUM>-<NUM> is disposed adjacent to the second carrier <NUM>, and the third lower mold <NUM>-<NUM> is disposed adjacent to the first carrier <NUM>.

Next, the first lower mold <NUM>-<NUM> is moved from the bridging mechanism <NUM> into the second carrier <NUM>, and the third lower mold <NUM>-<NUM> is moved from the bridging mechanism <NUM> into the first carrier <NUM>, as shown in <FIG>. In some embodiments, the first lower mold <NUM>-<NUM> is moved by the first conveying unit 103a to leave the first receiving space 103c and enter the second carrier <NUM>, and the third lower mold <NUM>-<NUM> is moved by the second conveying unit 103b to leave the second receiving space 103d and enter the first carrier <NUM>. As a result, the first lower mold <NUM>-<NUM> is conveyed from the first carrier <NUM> to the second carrier <NUM>, and the third lower mold <NUM>-<NUM> is conveyed from the second carrier <NUM> to the first carrier <NUM>. In other words, the bridging mechanism <NUM> is capable of exchanging the first lower mold <NUM>-<NUM> and the third lower mold <NUM>-<NUM> between the first carrier <NUM> and the second carrier <NUM>.

After moving the first lower mold <NUM>-<NUM> to the second carrier <NUM> and moving the third lower mold <NUM>-<NUM> to the first carrier <NUM>, the corresponding one of first upper molds 202a is tightly engaged with the third lower mold <NUM>-<NUM> on the first carrier <NUM> as shown in <FIG>, and the corresponding one of second upper molds 202b is tightly engaged with the first lower mold <NUM>-<NUM> on the second carrier <NUM> as shown in <FIG>.

Next, the first carrier <NUM> and the second carrier <NUM> are rotated in the first direction R1 and the second direction R2, respectively, as shown in <FIG>. In some embodiments, the first carrier <NUM> and the second carrier <NUM> are rotated at the predetermined interval. After the rotation, the first lower mold <NUM>-<NUM> and the corresponding one of the second upper molds 202b are disposed away from the bridging mechanism <NUM>, and the third lower mold <NUM>-<NUM> and the corresponding one of the first upper molds 202a are also disposed away from the bridging mechanism <NUM>.

In some embodiments, after the rotation, the second lower mold <NUM>-<NUM> and the corresponding one of first upper molds 202a are disposed adjacent to the second receiving space 103d, and the fourth lower mold <NUM>-<NUM> and the corresponding one of second upper molds 202b are disposed adjacent to the first receiving space 103c. In some embodiments, the second lower mold <NUM>-<NUM> is aligned with the second receiving space 103d, and the fourth lower mold <NUM>-<NUM> is aligned with the first receiving space 103c.

After the rotation of the first carrier <NUM>, the second lower mold <NUM>-<NUM> is disengaged with the corresponding one of the first upper molds 202a as shown in <FIG>. Similarly, after the rotation of the second carrier <NUM>, the fourth lower mold <NUM>-<NUM> is disengaged with the corresponding one of the second upper molds 202b as shown in <FIG>. That is, the second lower mold <NUM>-<NUM> is movable relative to the first carrier <NUM>, and the fourth lower mold <NUM>-<NUM> is movable relative to the second carrier <NUM>.

As described above and shown in <FIG>, the first polymeric material M1 has been injected into the first mold cavity 203a by the first injector <NUM> (in the operation S306 of <FIG>), and thus the first polymeric material M1 is disposed inside the disengaged second lower mold <NUM>-<NUM> of <FIG>.

Referring back to <FIG>, in the operation S308 of the injection molding method <NUM>, the lower mold <NUM> carrying the first polymeric material M1 is moved to the bridging mechanism <NUM>. Next, in the operation S310, the bridging mechanism <NUM> is rotated to convey the lower mold <NUM> carrying the first polymeric material M1 to the second carrier <NUM>. Next, in the operation S312, the conveyed lower mold <NUM> is engaged with the one of the second upper mold 202b, so as to form the second mold cavity 203b.

For example, as shown in <FIG>, the second lower mold <NUM>-<NUM> carrying the first polymeric material M1 is moved from the first carrier <NUM> into the second receiving space 103d by the second conveying unit 103b, and the fourth lower mold <NUM>-<NUM> is moved from the second carrier <NUM> into the first receiving space 103c by the first conveying unit 103a. Next, the bridging mechanism <NUM> is rotated in the third direction R3 to convey the second lower mold <NUM>-<NUM> and the fourth lower mold <NUM>-<NUM>, as shown in <FIG>. In some embodiments, the first carrier <NUM> and the second carrier <NUM> stop rotation temporarily during the rotation of the bridging mechanism <NUM>. In some embodiments, the bridging mechanism <NUM> is rotated so that the second lower mold <NUM>-<NUM> is disposed adjacent to the second carrier <NUM> and the fourth lower mold <NUM>-<NUM> is disposed adjacent to the first carrier <NUM>. In some embodiments, the rotation of the bridging mechanism <NUM> is similar to the step as described above and shown in <FIG>.

In some embodiments, the bridging mechanism <NUM> is rotated in the predetermined angle in a similar way as shown in <FIG> so that the second lower mold <NUM>-<NUM> is away from the first carrier <NUM> and the fourth lower mold <NUM>-<NUM> is away from the second carrier <NUM>. After the rotation in the predetermined angle, the second lower mold <NUM>-<NUM> and the fourth lower mold <NUM>-<NUM> are processed by one or more additional processing units (not shown) configured at or over the bridging mechanism <NUM>.

After the rotation of the bridging mechanism <NUM>, the second lower mold <NUM>-<NUM> is moved from the bridging mechanism <NUM> into the second carrier <NUM>, and the fourth lower mold <NUM>-<NUM> is moved from the bridging mechanism <NUM> into the first carrier <NUM>. In some embodiments, the fourth lower mold <NUM>-<NUM> is moved by the first conveying unit 103a to leave the first receiving space 103c and enter the first carrier <NUM>, and the second lower mold <NUM>-<NUM> is moved by the second conveying unit 103b to leave the second receiving space 103d and enter the second carrier <NUM>. As a result, the second lower mold <NUM>-<NUM> is conveyed from the first carrier <NUM> to the second carrier <NUM>, and the fourth lower mold <NUM>-<NUM> is conveyed from the second carrier <NUM> to the first carrier <NUM>. Thus, the second lower mold <NUM>-<NUM> carrying the first polymeric material M1 is moved to the second carrier <NUM> from the first carrier <NUM> through the bridging mechanism <NUM>.

After moving the fourth lower mold <NUM>-<NUM> to the first carrier <NUM>, the corresponding one of first upper molds 202a is tightly engaged with the fourth lower mold <NUM>-<NUM> on the first carrier <NUM>, as shown in the closed configuration of <FIG>. Similarly, after moving the second lower mold <NUM>-<NUM> to the second carrier <NUM>, the corresponding one of second upper molds 202b is tightly engaged with the second lower mold <NUM>-<NUM> on the second carrier <NUM> as shown in the closed configuration of <FIG>.

Next, the first carrier <NUM> and the second carrier <NUM> are rotated in the first direction R1 and the second direction R2, respectively. In some embodiments, the first carrier <NUM> and the second carrier <NUM> are rotated at the predetermined interval. After the rotation, the second lower mold <NUM>-<NUM> and the corresponding one of the second upper molds 202b are disposed away from the bridging mechanism <NUM>, and the fourth lower mold <NUM>-<NUM> and the corresponding one of the first upper molds 202a are also disposed away from the bridging mechanism <NUM>.

In some embodiments, the first carrier <NUM> is configured to continue to rotate in the first direction R1, so that the fourth lower mold <NUM>-<NUM> and the corresponding one of the first upper molds 202a are disposed under the first injector <NUM>, as shown in <FIG>. Similarly, the second carrier <NUM> is configured to continue to rotate in the second direction R2, so that the second lower mold <NUM>-<NUM> and the corresponding one of second upper molds 202b are disposed under the second injector <NUM>.

Referring back to <FIG>, in the operation S314 of the injection molding method <NUM>, after the lower mold <NUM> carrying the first polymeric material M1 is rotated under the second injector <NUM>, the second polymeric material M2 is injected into the second mold cavity 203b by the second injector <NUM>. Therefore, in the operation S316, an article including the first polymeric material M1 and the second polymeric material M2 is obtained.

For example, after the second lower mold <NUM>-<NUM> and the corresponding one of second upper molds 202b are rotated under the second injector <NUM> by the second carrier <NUM>, the second polymeric material M2 is injected from the second injector <NUM> into the second molding station 200b under the second injector <NUM> as shown in <FIG>. The second polymeric material M2 is injected into the second mold cavity 203b through the second sprue 204b. As described above, the second mold cavity 203b is defined by the second upper mold 202b and the corresponding lower mold <NUM> when the second molding station 200b is in the closed configuration. In some embodiments, the second polymeric material M2 includes thermoplastic polyurethane (TPU), polyurethane (PU), plastics or any other suitable materials. In some embodiments, the second polymeric material M2 includes a physical blowing agent such as supercritical fluid. In some embodiments, the physical blowing agent is gaseous nitrogen, carbon dioxide, etc. In some embodiments, the second polymeric material M2 is foamable, non-foamable or slightly foamable.

The first polymeric material M1 is different from the second polymeric material M2. In some embodiments, the first polymeric material M1 and the second polymeric material M2 have different materials, different physical properties, etc. In some embodiments, the first polymeric material M1 and the second polymeric material M2 have different densities, hardnesses and so on.

After injecting the second polymeric material M2 into the first mold cavity <NUM>, the second carrier <NUM> is rotated in the second direction R2 such that the second lower mold <NUM>-<NUM> and the corresponding one of second upper molds 202b are moved away from the second injector <NUM>. After moving the second lower mold <NUM>-<NUM> and the corresponding one of second upper molds 202b away from the second injector <NUM>, the corresponding one of second upper molds 202b is disengaged with the second lower mold <NUM>-<NUM> so that an article M including the first polymeric material M1 and the second polymeric material M2 can be taken out from the second lower mold <NUM>-<NUM>. In some embodiments, the article M is a part of a footwear (such as outsole, insole, midsole, etc.) or any other products.

After the article M is taken out from the second lower mold <NUM>-<NUM>, the first carrier <NUM> and the second carrier <NUM> continue to rotate, as described above. After the rotation, the first lower mold <NUM>-<NUM> and the third lower mold <NUM>-<NUM> have been exchanged by the bridging mechanism <NUM>, as shown in <FIG>. The first lower mold <NUM>-<NUM> is an empty mold from which the article M has be taken out, and the third lower mold <NUM>-<NUM> is the lower mold carrying the first polymeric material M1 injected by the first injector <NUM>. Furthermore, in order to convey the second lower mold <NUM>-<NUM> and the fourth mold <NUM>-<NUM> through the bridging mechanism <NUM>, the second lower mold <NUM>-<NUM> and the corresponding one of the second upper molds 202b are disposed adjacent to the first receiving space 103c of the bridging mechanism <NUM>, and the fourth mold <NUM>-<NUM> and the corresponding one of the first upper molds 202a are disposed adjacent to the second receiving space 103d of the bridging mechanism <NUM>.

In some embodiments, the bridging mechanism <NUM> (as shown in broken lines in <FIG>) can be idle, stopped, in not-in-use state, or even disconnected or removed from the injection molding system <NUM>, while the first carrier <NUM> and the second carrier <NUM> are operated individually and perform those relevant steps of the injection molding method as described above independently. The rotation of the first carrier <NUM> is independent from the rotation of the second carrier <NUM>.

In some embodiments, when the bridging mechanism <NUM> is in not-in-use state or removed, the first upper molds 202a and the lower molds <NUM> on the first carrier <NUM> are moved by the rotation of the first carrier <NUM>. When the first upper mold 202a and the corresponding lower mold <NUM> are conveyed and then disposed under the first injector <NUM>, the first polymeric material M1 is injected from the first injector <NUM> into the first mold cavity 203a through the first sprue 204a as shown in <FIG>. After the injection of the first polymeric material M1, the first upper mold 202a and the corresponding lower mold <NUM> are moved away from the first injector <NUM> by the rotation of the first carrier <NUM>. After moving away from the first injector <NUM>, the first upper mold 202a is disengaged from the corresponding lower mold <NUM>, so that an article having the first polymeric material M1 is formed inside the corresponding lower mold <NUM> and can be taken out from the corresponding lower mold <NUM>.

Similarly, when the bridging mechanism <NUM> is in not-in-use state or removed, the second upper molds 202b and the lower molds <NUM> on the second carrier <NUM> are moved by the rotation of the second carrier <NUM>. When the second upper mold 202b and the corresponding lower mold <NUM> are conveyed and then disposed under the second injector <NUM>, the second polymeric material M2 is injected from the second injector <NUM> into the second mold cavity 203b through the second sprue 204b as shown in <FIG>. After the injection of the second polymeric material M2, the second upper mold 202b and the corresponding lower mold <NUM> are moved away from the second injector <NUM> by the rotation of the second carrier <NUM>. After moving away from the second injector <NUM>, the second upper mold 202b is disengaged from the corresponding lower mold <NUM>, so that an article having the second polymeric material M2 is formed inside the corresponding lower mold <NUM> and can be taken out from the corresponding lower mold <NUM>.

When the bridging mechanism <NUM> is in not-in-use state or removed, the first polymeric material M1 and the second polymeric material M2 are same or different materials. In some embodiments, the first polymeric material M1 and the second polymeric material M2 have same or different physical properties.

In some embodiments, the injection molding system <NUM> is controlled by a controller (not shown). The controller is configured to control the rotation of the first carrier <NUM>, the rotation of the second carrier <NUM>, and the rotation of the bridging mechanism <NUM>, e.g., the direction, angle and speed during the rotation, so as to form an article including more than one portion having different physical or functional properties. Furthermore, the controller is configured to idle or stop the bridging mechanism <NUM>, so as to form an article including single physical or functional property.

According to the embodiments of the present disclosure, the bridging mechanism <NUM> is used to convey the lower molds between the first carrier <NUM> and the second carrier <NUM> by rotation or movement of the bridging mechanism <NUM>. Through the bridging mechanism <NUM>, the two different injections of the first injector <NUM> and the second injector <NUM> are performed continuously on the first carrier <NUM> and the second carrier <NUM>, thereby decreasing manufacturing time of the article including more than one portion having different physical or functional properties.

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 first carrier (<NUM>) configured to hold a first mold;
a first injector (<NUM>) disposed over the first carrier and configured to inject a first polymeric material;
a second carrier (<NUM>) configured to hold a second mold;
a second injector (<NUM>) disposed over the second carrier and configured to inject a second polymeric material; characterized in that it further comprises
a bridging mechanism (<NUM>) disposed between and moveable relative to the first carrier and the second carrier, and configured to receive a third mold from the first carrier or the second carrier and convey the third mold between the first carrier and the second carrier.