Patent Description:
Foamed polymeric material has many advantages, such as high strength, low weight, impact resistance, thermal insulation, and others. Articles can be made by injection 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 the mixture into a cavity of a mold, and the mixture is foamed and cooled in the cavity to form the article.

However, it is necessary to improve the properties of the article made by the injection molding system, such as fixing the molding device at a specific position. Therefore, there is a need for improvements to structures of the injection-molding system and the method for using the same.

<CIT> an apparatus generally comprising a mold clamping device including a mold clamping ram vertically operable toward a mold receiving chamber, an injection nozzle directed into the mold receiving chamber, and one or more metal molds each provided with a mold opening-and-closing device and mounted on a horizontally reciprocable plate entering into and retracting out of the mold receiving chamber, and the process is so organized that when one of the metal mold is transported, in its closed state, into the mold receiving chamber under a horizontal movement of the reciprocable plate, the mold clamping ram is operated for clamping the metal mold and a plastic material is injected into the mold cavity of the metal mold through the injection nozzle, and when the reciprocable plate moves out to another position, the metal mold thus injected is opened by means of the mold opening-and-closing device and the molded product is delivered. <CIT> discloses that by the movement of a press rod, a movable pressure plate and a lower mold are raised and consequently compression springs are compressed by a movable plate so that the resiliency is stored in the compression springs. When the pressure rod is moved upwards by the predetermined distance, a columnar spacer is released from the drilled hole of a rotary block <NUM>. At this time point, rubber material is poured from an injection unit into a mold. After that, the rotary block, which is fixed in a fixed block, is rotatingly driven by a pivoting device so as to shift the position of the drilled hole from the columnar spacer in order to release the pressing with an external pressing device. Because the columnar spacer is supported on the rotary block without being inserted in the drilled hole, the lower mold hardly descends and the mold clamping state is maintained by the resilience of the compression springs. <CIT> discloses a kind of multi-model plastic injection machine that is used for producing plastic articles by injection molding. The common plastic injection machine has only one model, and needs injecting plastic, maintaining pressure, and cooling to get one production. So the common plastic injection machine costs much time and limits the productivity. The new machine provided by the invention can improve productivity very much. There are many model locating slots on the rotating worktable of the plastic injection machine. At two sides of each model are oil cylinders A and B that used to open and close the model. A round fluted disc is on fixed board below the locking model, and it occludes the high precision servo mechanic gear. Rotating scope of the round fluted disc is <NUM>, and the angle of the rotating worktable is <NUM> per time in counter-clockwise. There are also hydraulic cylinder for propping out the model and two electromagnetic loops on the bottom of the fixed board of the locking model. On the other side of the fixed board is a hydraulic cylinder for propping out pressure maintaining board, on the front of which is a propelling head. <CIT> discloses an injection molding machine which is provided in an injection molding system wherein a plurality of molds for injection molding each forming a cavity and a carrying means carrying the molds successively in the specified order of a heating station, an injection station, a gradually cooling station and a removal station of the molded item are provided and injects and fills a molten resin into a cavity of each mold by means of an injection unit under a condition where a plurality of the molds carried to the injection station are fixed on a specified fixing stage. In addition, it is constituted in such a way that each mold-clamping mechanism is provided on all the fixing positions on the fixing stage where a plurality of the molds are fixed. In addition, it is possible to provide a pressing mechanism which each presses from the perpendicular direction to the mold-clamping direction at each fixing position. <CIT> discloses a number of split moulds or mould carriers are supported on a rotatable turret and brought in turn to a charging position where the moulds or carriers are firmly clamped by means of alignment rings having tapering surfaces coacting with complementary faces on the moulds or carriers. A platen, serving as a mould conveyer, is movable vertically by rams (preferably fluid-operated). The ring ensures accurate register with the nozzle of an injection cylinder. A peg projecting from each mould carrier is secured by a captive nut to a spigot on the turret. Each carrier comprises two hinged portions held closed by a clamp. <CIT> discloses a kind of a molding to be molded is changed from A kind to B kind, it is given a command from an outside molding indication device. As a result, it is changed to an operation mode which may not conduct an injection while clamping a mold at a clamping and injecting station, and as the mold passed through a mold opening station reaches a station, a clamper releases the clamp of the mold; on the other hand, a push-pull cylinder pulls the mold in a transfer table, and the mold is forwarded in the space of a storage box by another push-pull cylinder. Furthermore, as the storage box removes in a upper and lower direction, a push-pull cylinder draws out a mold of B kind from the storage box onto a mounting table, hence it is clamped by being forwarded in onto a turn table. <CIT> discloses a molding device. <CIT> discloses a vertical injection machine for molding soles, technical articles and the like, of the type which comprises a footing which supports a plurality of presses which have a vertical closing motion and are provided with mold holders for supporting corresponding molds; the molds are fed by an injection assembly arranged above the presses in order to inject substantially vertically; there are means for the relative mutual motion of the vertical injection assembly and of at least portions of the mold holders; the machine is provided with a control and actuation assembly arranged adjacent to the presses. The presses, with the respective mold holders, are arranged in a line and are mutually adjacent, so as to form a single row, so that they can be accessed conveniently from both sides for operations for removing the finished product, for positioning inserts, and for cleaning and maintenance.

One purpose of the present invention is to provide an extruding system and a method of extruding a mixture. The object of the invention is solved by a molding device according to claim <NUM> and a molding method according to claim <NUM>.

Further embodiments of the invention are defined by the subject matter of the dependent claims.

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.

<FIG> is a schematic cross-sectional view illustrating an injection molding system <NUM>. In some embodiments, the injection molding system <NUM> includes a molding device <NUM>, a plunger <NUM> and an injection station <NUM>. In some embodiments, the injection station <NUM> is configured to receive the molding device <NUM>. The platform 105a is configured to dispose the molding device <NUM>. The injector 105b is configured to discharge a fluid or liquid from an outlet 105c. In some embodiments, a first opening 105d extending through the platform 105a is included. In accordance with the invention the injector 105b is disposed above the first opening 105d. In some embodiments, the injector 105b is overlapped with the first opening 105d from a top view. In some embodiments, the injection station <NUM> further includes a chamber 105e. The platform 105a and the injector 105b are disposed above the chamber 105e. The molding device <NUM> is disposed in the injection station <NUM>.

In some embodiments, the molding device <NUM> is provided or received as shown in <FIG>. The molding device <NUM> includes a mold cavity 101e and a clamping unit <NUM> for clamping the molding device <NUM>. In some embodiments, the molding device <NUM> is configured for forming an article in the mold cavity 101e, such as a formed article. In some embodiments, the fluid or liquid is injected into the mold cavity 101e and then the article is formed in the mold cavity 101e after a period of time.

The mold cavity 101e is defined by a first mold base 101d and a second mold base 101c disposed over and corresponding to the first mold base 101d. In some embodiments, the molding device <NUM> further includes a first mold 101b disposed in the first mold base 101d and a second mold 101a disposed over and corresponding to the first mold 101b. In some embodiments, the second mold 101a corresponds to the first mold 101b in some configurations such as dimension, shape or the like. The second mold 101a can be placed on and engaged with the first mold 101b. In some embodiments, the mold cavity 101e is defined by the second mold 101a and the first mold 101b. In some embodiments, the second mold base 101c corresponds to the first mold base 101d in some configurations such as dimension, shape or the like. The second mold base 101c can be placed above the first mold base 101d.

In some embodiments, the molding device <NUM> further includes a first passage 101f extending through the second mold 101a and the second mold base 101c. The first passage 101f is configured to allow the fluid or liquid flowing through. In some embodiments, the first passage 101f is communicable with the mold cavity 101e.

In some embodiments, the first mold base 101d further includes a second opening <NUM> configured to receive at least a portion of the plunger <NUM>. In some embodiments, the second opening <NUM> is overlapped with the first opening 105d from a top view. In some embodiments, the fluid or liquid is forced and pushed into the mold cavity 101e through the outlet 105c by an injecting force. In some embodiments, a direction of the injecting force is from the injector 105b towards the second opening <NUM>.

In some embodiments, the clamping unit <NUM> is disposed between the first mold base 101d and the second mold base 101c. The second mold base 101c is coupled with the first mold base 101d by the clamping unit <NUM>. In some embodiments, the clamping unit <NUM> is adjacent to the first mold 101b and the second mold 101a. In some embodiments, the molding device <NUM> includes a plurality of clamping units <NUM>. In some embodiments, the clamping unit <NUM> is configured to apply a clamping force to the second mold 101a and the first mold 101b. The clamping force can be applied on the second mold base 101c towards the first mold base 101d or vice versa.

The second mold 101a and the first mold 101b can maintain engagement with each other by the clamping force provided by the clamping unit <NUM>. In other words, the molding device <NUM> can maintain in a closed configuration as shown in <FIG> by the clamping force from the clamping unit <NUM>. In some embodiments, the clamping force can be applied continuously throughout an injection molding process. In some embodiments, the clamping force is in a range of about <NUM> Newton (N) to 15N. In some embodiments, the clamping force is about 10N.

In some embodiments, a gas is initially injected into the mold cavity 101e, and the clamping force is applied to the molding device <NUM> by the clamping unit <NUM> in order to maintain the mold cavity 101e at a predetermined pressure. In some embodiments, the molding device <NUM> is maintained in the closed configuration by the clamping force from the clamping unit <NUM> throughout the injection molding process.

In some embodiments, the fluid or liquid discharged from the outlet 105c includes a polymeric material. In some embodiments, the polymeric material is flowable along the injector 105b and dischargeable from the outlet 105c. In some embodiments, the fluid or liquid includes a mixture of the polymeric material and a blowing agent. In some embodiments, the flowable polymeric material is formed by hot-melting or any other suitable processes. The technical details of hot-melting are known in the prior art, and description thereof is omitted herein.

In some embodiments, the polymeric material includes ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethanes (TPU), thermoplastic polyester elastomer (TPEE) or the like. 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. The technical details of mixing the polymeric material and the blowing agent are known in the prior art, and description thereof is omitted herein.

According to the invention, the molding device <NUM> further includes a locking device103. In some embodiments, the locking device <NUM> is configured to lock the molding device <NUM> on the platform 105a. In some embodiments, the locking device <NUM> is configured to facilitate a temporarily engagement of the molding device <NUM> to the injection station <NUM>. In some embodiments, the locking device <NUM> is used to prevent movement of the molding devices <NUM> during the injection of the fluid or the liquid into the mold cavity 101e. The locking device <NUM> can be disposed at any suitable position.

In some embodiments, the locking device <NUM> includes a first locking element 103a disposed on the molding device <NUM> and a second locking element 103b disposed on the platform 105a and corresponding to the first locking element 103a. In some embodiments, the first locking element 103a is disposed on the first mold base 101d. In some embodiments, the first and second locking elements 103a, 103b can be clamped to or engage with each other, but the disclosure is not limited thereto. In some embodiments, the first locking element 103a is overlapped with the second locking element 103b when the first and second locking elements 103a, 103b are clamped to or engage with each other.

According to the invention, the first locking element 103a is a part of the molding device <NUM>, while the second locking element 103b is a part of the platform 105a. In some embodiments, the first locking element 103a and the second locking element 103b are configured complementary with each other. In some embodiments, the first locking element 103a protrudes from the molding device <NUM>, and the second locking element 103b is configured to receive the first locking element 103a. In some embodiments, the second locking element 103b protrudes from the platform 105a, and the first locking element 103a is configured to receive the second locking element 103b. The position and number of the first locking element 103a may be adjusted according to requirements, and are not particularly limited. The position and number of the second locking element 103b may also be adjusted according to requirements, and are not particularly limited. In some embodiments, the position and number of the second locking element 103b correspond to the position and number of the first locking element 103a.

The plunger <NUM> includes a base 104a and a rod 104b. The plunger <NUM> is configured to provide a plunging force. In some embodiments, the plunger <NUM> is a hydraulic plunger. In some embodiments, the rod 104b is extendable and retractable. In some embodiments, the rod 104b is movable vertically. In some embodiments, the plunger can provide the plunging force in a range of about 30N to 80N. In some embodiments, the plunging force is about 50N.

In some embodiments, the plunger <NUM> is movable relative to the injection station <NUM>. In some embodiments, the plunger <NUM> is separated from the injection station <NUM>, and may be moved into the injection station <NUM>. In some embodiments, the plunger <NUM> is not movable and is initially fixed in the injection station <NUM>. In some embodiments, the plunger <NUM> is fixedly disposed under the platform 105a, and the rod 104b is vertically aligned with the first opening 105d. In some embodiments, the plunger <NUM> is initially fixed in the chamber 105e.

<FIG> is a flowchart showing a method M10 of injection molding method in accordance with some embodiments of the present disclosure. The method M10 includes several operations: (O101) providing an injection station including a platform and an injector disposed over the platform, wherein the platform includes a first opening extending through the platform; (<NUM>) conveying a molding device to the injection station and disposing the molding device between the injector and the platform, wherein the molding device includes a first mold, a second mold over the first mold and a mold cavity defined by the first mold and the second mold; (<NUM>) disposing a plunger under the molding device and the platform, wherein the plunger includes a base and a rod extendable toward the molding device and retractable toward the base; (<NUM>) moving the injector towards the molding device to communicate with the mold cavity; (<NUM>) applying a plunging force on the molding device by extending the rod through the first opening towards the molding device; and (<NUM>) injecting a molding material from the injector into the mold cavity.

In order to illustrate concepts and the method M10 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. The various operations and the thus formed articles of the injection molding method can be in various configurations. In some embodiments, the method M10 is implemented by the injection molding system <NUM> as shown in <FIG>, and <FIG> are schematic cross-sectional views of various stages of the injection molding method.

In some embodiments, the method M10 of injection molding method includes operation O101, which includes providing the injection station <NUM> as shown in <FIG>. The injection station <NUM> includes a platform 105a and an injector 105b disposed over the platform 105a. In some embodiments, the platform 105a includes a first opening 105d extending through the platform 105a.

In some embodiments, the method M10 of injection molding method includes operation <NUM>, which includes conveying the molding device <NUM> to the injection station <NUM> and disposing the molding device <NUM> between the injector 105b and the platform 105a as shown in <FIG>. In some embodiments, the molding device <NUM> is disposed in the injection station <NUM>. In some embodiments, the molding device <NUM> at least includes the first mold 101b, the second mold 101a over the first mold 101b and the mold cavity 101e defined by the first mold 101b and the second mold 101a.

The molding device <NUM> is moved towards the injection station <NUM> and placed on the platform 105a as shown in <FIG>. During the movement of the molding device <NUM>, the molding device <NUM> is maintained in the closed configuration by the clamping unit <NUM>. In some embodiments, the mold cavity 101e is maintained at the predetermined pressure during the movement of the molding device <NUM>. In some embodiments, the second mold 101a and the first mold 101b can maintain engagement with each other by the clamping force provided by the clamping unit <NUM>. In some embodiments, the clamping force can be applied continuously throughout an injection molding process. In some embodiments, the clamping force is in a range of about <NUM> Newton (N) to 15N. In some embodiments, the clamping force is about 10N.

In some embodiments, the molding device <NUM> is engaged with the platform 105a. In some embodiments, the first locking element 103a is vertically aligned with the second locking element 103b. In some embodiments, the second opening <NUM> is overlapped with the first opening 105d from a top view.

In some embodiments, the outlet 105c of the injector 105b is disposed above the first passage 101f of the molding device <NUM>. In some embodiments, a second passage 104c including the first opening 105d and the second opening <NUM> is formed after placing the molding device <NUM> on the platform 105a. In some embodiments, the second passage 104c extends through the platform 105a and the first mold base 101d. In some embodiments, the first passage 101f is overlapped with the second passage 104c from a top view. In some embodiments, the injector 105b may be extended into and be retracted from the molding device <NUM>. In some embodiments, the injector 105b and the outlet 105c are overlapped with the first passage 101f from a top view.

In some embodiments, the method M10 of injection molding method includes operation <NUM>, which includes disposing the plunger <NUM> under the molding device <NUM> and the platform 105a. In some embodiments, the plunger <NUM> includes a base 104a and a rod 104b extendable toward the molding device <NUM> and retractable toward the base 104a. In some embodiments, the method M10 further includes aligning the injector 105b with the rod 104b before and during injecting the fluid or the liquid.

The plunger <NUM> is moved towards the injection station <NUM> and placed under the platform 105a as shown in <FIG>. In some embodiments, the plunger <NUM> is disposed in the injection station <NUM> and under the molding device <NUM>. In some embodiments, the plunger <NUM> is in the retracted configuration during the movement. In some embodiments, the plunger <NUM> is fixedly disposed under the molding device <NUM> and the first opening 105d. In some embodiments, the rod 104b of the plunger <NUM> is aligned with the second passage 104c after movement. In some embodiments, the plunger <NUM> is in a retracted configuration as shown in <FIG>. In some embodiments, the plunger <NUM> is disposed in the injection station <NUM> and under the molding device <NUM>. In some embodiments, the plunger <NUM> is disposed under the platform 105a. In some embodiments, the plunger <NUM> is disposed in the chamber 105e. In some embodiments, the rod 104b is vertically aligned with the first opening 105d. In some embodiments, the rod 104b is extendable through the first opening 105d. In some embodiments, the rod 104b is extended and at least a portion of the rod 104b is disposed in the second opening <NUM>. In some embodiments, the rod 104b is vertically aligned with the injector 105b and the outlet 105c.

In some embodiments, the molding device <NUM> and the plunger <NUM> are conveyed into the injection station <NUM> simultaneously. In some embodiments, the molding device <NUM> and the plunger <NUM> are configured as a molding module <NUM>. In some embodiments, the molding device <NUM> and the plunger <NUM> are moved together into the injection station <NUM>. In some embodiments, the molding device <NUM> is disposed above and aligned with the plunger <NUM> before moving into the injection station <NUM> as shown in <FIG>. The second opening <NUM> of the first mold base 101d is vertically aligned with the rod 104b of the plunger <NUM>.

<FIG> is a schematic cross-sectional view illustrating the operations <NUM> and <NUM> of the method M10 in accordance with some embodiments of the present disclosure. In some embodiments, the method M10 of injection molding method includes operation <NUM>, which includes moving the injector 105b towards the molding device <NUM> to communicate with the mold cavity 101e.

In some embodiments, the injector 105b is moved towards the molding device <NUM> after the engagement of the molding device <NUM> with the platform 105a. In some embodiments, the injector 105b is moved towards the molding device <NUM> after the engagement of the first locking element 103a and the second locking element 103b. In some embodiments, the outlet 105c of the injector 105b is engaged with the first passage 101f, such that the fluid or liquid can flow from the injector 105b into the mold cavity 101e through the first passage 101f.

In some embodiments, the method M10 of injection molding method includes operation <NUM>, which includes applying a plunging force on the molding device <NUM> by extending the rod 104b through the first opening 105d towards the molding device <NUM>. In some embodiments, the rod 104b extends towards the molding device <NUM> to provide the plunging force on the molding device <NUM>. In some embodiments, the rod 104b extends and passes through the second passage 104c to contact the first mold 101b and press the first mold 101b towards the second mold 101a. The rod 104b contacts the molding device <NUM> during the application of the plunging force. The plunging force is applied on the first mold 101b towards the second mold 101a. In some embodiments, the upward plunging force is applied to the molding device <NUM>. In some embodiments, the plunging force is in a range of about 30N to about 80N. In some embodiments, the plunging force is about 50N. The second mold 101a and the first mold 101b are tightly engaged with each other during the application of the plunging force. In some embodiments, the plunger <NUM> is in an extended configuration as shown in <FIG>.

In some embodiments, the method M10 of injection molding method further includes locking the molding device <NUM> on the platform 105a before injection. Since the molding device <NUM> is engaged with the platform 105a by the locking device <NUM>, a downward reaction force from the molding device <NUM> or the second mold base 101c opposing the upward plunging force is generated. As a result, the molding device <NUM> is under a higher pressure upon the application of the plunging force, compared with the molding device <NUM> maintained in the predetermined pressure (in the closed configuration) by the clamping unit <NUM>. In some embodiments, the plunging force is provided prior to and/or during an injection of the fluid or liquid from the injector 105b into the mold cavity 101e.

<FIG> is a schematic cross-sectional view illustrating the operation <NUM> of the method M10 in accordance with some embodiments of the present disclosure. In some embodiments, the method M10 of injection molding method includes operation <NUM>, which includes injecting a molding material from the injector 105b into the mold cavity 101e. In some embodiments, the fluid or liquid includes the molding material.

The fluid or liquid is discharged and flowed from the injector 105b into the mold cavity 101e as shown in <FIG>. In some embodiments, the fluid or liquid forms an article within the mold cavity 101e. During the discharge of the fluid or liquid from the injector 105b into the mold cavity 101e, the plunger <NUM> keeps applying the plunging force on the molding device <NUM>, so that the second mold 101a keeps engaging with the first mold 101b and the outlet 105c keeps engaging with the first passage 101f. In some embodiments, the clamping force is applied to clamp the first mold 101b and the second mold 101a during the conveying of the molding device <NUM> and the injection of the fluid or liquid. During the discharge of the fluid or liquid from the injector 105b into the mold cavity 101e, the injector 105b and the outlet 105c are overlapped with the first passage 101f, the second passage 104c and the rod 104b from a top view.

<FIG> is a schematic cross-sectional view illustrating the operation of the method M10 in accordance with some embodiments of the present disclosure. In some embodiments, when the injection of the fluid or liquid into the mold cavity 101e is accomplished, the injector 105b is withdrawn and moved away from the molding device <NUM> as shown in <FIG>. In some embodiments, when the injection of the fluid or liquid into the mold cavity 101e is accomplished, the rod 104b is retracted towards the base 104a and the plunging force is withdrawn by retracting the rod 104b. The outlet 105c is disengaged from the first passage 101f, and the rod 104b is moved away from the molding device <NUM>. After the withdrawn of the plunging force, the molding device <NUM> is continuously maintained in the closed configuration and under the predetermined pressure.

<FIG> is a schematic cross-sectional view illustrating the operations of the method M10 in accordance with some embodiments of the present disclosure. In some embodiments, as shown in <FIG>, the method M10 of injection molding method further includes conveying the molding device <NUM> away from the injection station <NUM> after the withdrawal of the injector 105b and the retraction of the rod 104b. In some embodiments, the method M10 further includes unlock the molding device <NUM> from the platform 105a after injection and before conveying the molding device <NUM> away. In some embodiments, the first locking element 103a and the second locking element 103b are disengaged from each other before moving the molding device <NUM> out of the injection station <NUM>.

According to the invention, the molding device <NUM> is moved away from the platform 105a by a conveying mechanism such as conveying belt, roller, etc. When the molding device <NUM> is moved out of the injection station <NUM>, the molding device <NUM> is continuously maintained in the closed configuration and under the predetermined pressure. The clamping force is continuously applied to the molding device <NUM> by the clamping unit <NUM> during or after moving the molding device <NUM> out of the injection station <NUM>.

In some embodiments, after the accomplishment of injecting the fluid or liquid from the injector 105b into the mold cavity 101e, the plunger <NUM> is moved away from the injection station <NUM> as shown in <FIG>. In some embodiments, after the accomplishment of injecting the fluid or liquid from the injector 105b into the mold cavity 101e, the molding device <NUM> and the plunger <NUM> are conveyed out of the injection station <NUM> simultaneously. In some embodiments, after the accomplishment of injecting the fluid or liquid from the injector 105b into the mold cavity 101e, the molding module <NUM> is moved away from the injection station <NUM>.

In some embodiments, the molding device <NUM> is moved out of the injection station <NUM> for cooling. The molding device <NUM> is cooled for a predetermined duration to form the article in the mold cavity 101e. In some embodiments, the molding device <NUM> opens after the formation of the article. The clamping unit <NUM> is released to open the molding device <NUM>. The second mold 101a and the first mold 101b are moved away from each other, and then the article formed in the mold cavity 101e can be obtained.

As discussed above, the molding device <NUM> is required to maintain in the predetermined pressure throughout the injection molding process, except during the injection of the fluid or liquid from the injector 105b into the mold cavity 101e. The molding device <NUM> is required to be under a higher pressure only during the injection of the fluid or liquid from the injector 105b into the mold cavity 101e. In other words, it is not necessary to continuously maintain a high pressure or high force on the molding device <NUM> throughout the injection molding process. Therefore, lifespan of the molding device <NUM> can be improved or increased, energy consumed by the above injection molding system <NUM> or method can be lowered, and overall dimension or structural configuration of the molding device <NUM> can be more compact, lighter and simpler. Performance of the injection molding system or injection molding method can be more efficient and faster.

<FIG> is a flowchart showing a method M20 of injection molding method in accordance with some embodiments of the present disclosure. The method M20 includes several operations: (<NUM>) providing a carrier, wherein a first molding device and a second molding device are held by the carrier; (O202) providing an injection station including a platform and an injector disposed over the platform, wherein the platform includes a first opening extending through the platform; (O203) providing a plunger disposed under the platform, wherein the plunger includes a base and a rod extendable from and retractable toward the base; (O204) moving the first molding device into the injection station and disposing the first molding device between the injector and the platform; (O205) providing a plunging force to the first molding device by extending the rod through the first opening to contact the first molding device; (O206) injecting a molding material from the injector into the first molding device; (O207) withdrawing the injector and the rod from the first molding device after injection; (O208) moving the first molding device from the injection station; and (O209) moving the second molding device into the injection station and disposing the second molding device between the injector and the platform.

In order to illustrate concepts and the method M20 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. The various stages of the injection molding method can be in various configurations as shown in any of <FIG>.

<FIG> are schematic top views illustrating injection molding systems <NUM>, <NUM>. In some embodiments, the injection molding method M10 as described above or illustrated in <FIG> is implemented by the injection molding system <NUM>. In some embodiments, the injection molding method M20 is implemented by the injection molding system <NUM> or the injection molding system <NUM>.

<FIG> and <FIG> are schematic top views illustrating an injection molding system <NUM> of the method M20 in accordance with some embodiments of the present disclosure. Initially, in some embodiments, as shown in <FIG>, the method M20 of injection molding method includes step <NUM>, which includes providing a carrier <NUM>, wherein a first molding device <NUM>-<NUM> and a second molding device <NUM>-<NUM> are held by the carrier <NUM>. In some embodiments, the method M20 of injection molding method further includes step O202, which includes providing an injection station <NUM> including a platform 105a and an injector 105b disposed over the platform 105a, wherein the platform 105a includes a first opening 105d extending through the platform 105a. In some embodiments, the method M20 of injection molding method includes step O203, which includes providing a plunger <NUM> disposed under the platform 105a, wherein the plunger <NUM> includes a base 104a and a rod 104b extendable from and retractable toward the base 104a. In some embodiments, the method M20 of injection molding method includes step O204, which includes moving the first molding device <NUM>-<NUM> into the injection station <NUM> and disposing the first molding device <NUM>-<NUM> between the injector 105b and the platform 105a. In some embodiments, the method M20 of injection molding method includes step O205, which includes providing a plunging force to the first molding device <NUM>-<NUM> by extending the rod 104b through the first opening 105d to contact the first molding device <NUM>-<NUM>. In some embodiments, the method M20 of injection molding method includes step O206, which includes injecting a molding material from the injector 105b into the first molding device <NUM>-<NUM>. In some embodiments, the method M20 of injection molding method includes step O207, which includes withdrawing the injector 105b and the rod 104b from the first molding device <NUM>-<NUM> after injection.

In some embodiments, as shown in <FIG>, an injection molding system such as the injection molding system <NUM> shown in <FIG> and <FIG> is arranged in the rotatable carrier <NUM>. In some embodiments, each of the first and second molding devices <NUM>-<NUM>, <NUM>-<NUM> is in configuration similar to the molding device <NUM> described above or illustrated in <FIG> and <FIG>. In some embodiments, the injection station <NUM> is in configuration similar to the one described above or illustrated in <FIG> and <FIG>. In some embodiments, the plunger <NUM> is in configuration similar to the one described above or illustrated in <FIG> and <FIG>.

In some embodiments, several molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> are arranged on the carrier <NUM>. In some embodiments, the carrier <NUM> includes several holders 201a for holding molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> or a part of the molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>. It is readily understood that the carrier <NUM> can include any suitable number of holders 201a. In some embodiments, each of the holders 201a can hold the corresponding molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>. For example as shown in <FIG>, the first and second molding devices <NUM>-<NUM>, <NUM>-<NUM> are held by two holders 201a respectively. In some embodiments, the number of the holders 201a is more than or equal to the number of the molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>.

The injection station <NUM> is disposed across the carrier <NUM> and several molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> are arranged on the carrier <NUM>. In some embodiments, a portion of the carrier <NUM> is disposed in the injection station <NUM>.

In some embodiments, a portion of the carrier <NUM> is disposed between the platform 105a and the injector 105b. The molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> are conveyed into the injection station <NUM> one by one by the rotation of the carrier <NUM>. For example, the first molding devices <NUM>-<NUM> is moved and placed on the platform 105a of the injection station <NUM>, and then the injection molding method M10 as described above or shown in <FIG> and <FIG> is performed on the first molding device <NUM>-<NUM>. In some embodiments, the first molding device <NUM>-<NUM> is moved into the injection station <NUM> by rotation of the carrier <NUM>. In some embodiments, the carrier <NUM> is rotated in a suitable speed or by a suitable force, such that the vibration of the molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> during the conveying is minimized or even prevented. In some embodiments, the carrier <NUM> is rotated in a predetermined interval, such as an angular distance between adjacent holders 201a. In some embodiments, the carrier <NUM> is rotatable about a center C1 of the carrier <NUM>.

In some embodiments, the method M20 includes moving the plunger <NUM> to dispose under the carrier <NUM> and the injection station <NUM> while the carrier <NUM> is stationary, or moving the carrier <NUM> to dispose the plunger <NUM> under the carrier <NUM> while the plunger <NUM> is stationary. In some embodiments, the plunger <NUM> is moved into the injection station <NUM> and disposed under the platform 105a before or after the placement of the first molding devices <NUM>-<NUM> on the platform 105a. In some embodiments, the injection station <NUM> and the plunger <NUM> are movable, and the carrier <NUM> is stationary. In some embodiments, the plunger <NUM> is fixedly disposed under the carrier <NUM> before the placement of the first molding devices <NUM>-<NUM> on the platform 105a. In some embodiments, the plunger <NUM> is fixedly disposed in the injection station <NUM> before the placement of the first molding devices <NUM>-<NUM> on the platform 105a. In some embodiments, the platform 105a is fixedly disposed under the carrier <NUM>, and the injector 105b is fixedly disposed over the carrier <NUM> and overlapped with the first opening 105d from a top view. The carrier <NUM> is movable relative to the injection station <NUM>, and the injection station <NUM> is stationary relative to the carrier <NUM>.

In some embodiments, as shown in <FIG>, the method M20 of injection molding method includes step O208, which includes moving the first molding device <NUM>-<NUM> from the injection station <NUM>. Further, the method M20 of injection molding method includes step O209, which includes moving the second molding device <NUM>-<NUM> into the injection station <NUM> and disposing the second molding device <NUM>-<NUM> between the injector 105b and the platform 105a.

After the accomplishment of the injection molding method M10, in some embodiments, the first molding device <NUM>-<NUM> inside the injection station <NUM> is moved out of the injection station <NUM> by the rotation of the carrier <NUM>. Simultaneously, the second molding device <NUM>-<NUM> adjacent to the first molding device <NUM>-<NUM> is moved into the injection station <NUM>. The injection molding method M10 as described above or shown in <FIG> and <FIG> is performed for the second molding device <NUM>-<NUM>.

In some embodiments, the carrier <NUM> is in an annular shape. In some embodiments, the carrier <NUM> is turntable. In some embodiments, the carrier <NUM> can be rotated clockwisely or anti-clockwisely.

<FIG> are schematic top views illustrating an injection molding system <NUM> of the method M20 in accordance with some embodiments of the present disclosure. In some embodiments, as shown in <FIG>, the injection molding system <NUM> includes a conveying belt <NUM>, and several molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> are carried by the conveying belt <NUM>. In some embodiments, the injection station <NUM> is disposed across a portion of the conveying belt <NUM> and the molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> are arranged on the conveying belt <NUM>. In some embodiments, a portion of the conveying belt <NUM> is disposed between the platform 105a and the injector 105b. In some embodiments, one of the molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> is disposed between the platform 105a and the injector 105b.

In some embodiments, as shown in <FIG>, an injection molding system such as the injection molding system <NUM> shown in <FIG> and <FIG> is arranged in the conveying belt <NUM>. In some embodiments, each of the first and second molding devices <NUM>-<NUM>, <NUM>-<NUM> is in configuration similar to the molding device <NUM> described above or illustrated in <FIG> and <FIG>. In some embodiments, the injection station <NUM> is in configuration similar to the one described above or illustrated in <FIG> and <FIG>. In some embodiments, the plunger <NUM> is in configuration similar to the one described above or illustrated in <FIG> and <FIG>.

The molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> are conveyed into the injection station <NUM> one by one by the movement of the conveying belt <NUM>. For example, the first molding device <NUM>-<NUM> is moved and placed on the platform 105a of the injection station <NUM>, and then the injection molding method M10 as described above or shown in <FIG> is performed. In some embodiments, the plunger <NUM> is moved into the injection station <NUM> and disposed under the platform 105a before or after the placement of the first molding device <NUM>-<NUM> on the platform 105a.

In some embodiments, the conveying belt <NUM> includes several holders 202a for holding a molding device or a part of the molding device. It is readily understood that the conveying belt <NUM> can include any suitable number of holders 202a. In some embodiments, each of the holders 202a can hold the corresponding molding devices <NUM>. For example as shown in <FIG>, the first and second molding devices <NUM>-<NUM>, <NUM>-<NUM> are held by two holders 202a respectively. In some embodiments, the number of the holders 202a is more than or equal to the number of the molding devices <NUM>.

After the accomplishment of the injection molding method M10, as shown in <FIG>, the first molding device <NUM>-<NUM> inside the injection station <NUM> is moved out of the injection station <NUM> by the movement of the conveying belt <NUM>. Simultaneously, another molding device <NUM> such as the second molding device <NUM>-<NUM> is moved into the injection station <NUM>. The injection molding method M10 as described above or shown in <FIG> is performed for the second molding device <NUM>-<NUM>. In some embodiments, the conveying belt <NUM> is in a linear shape.

<FIG> and <FIG> are schematic top views illustrating the injection molding system <NUM> of the method M20 in accordance with some embodiments of the present disclosure. In some embodiments, as shown in <FIG> and <FIG>, the injection station <NUM> is arranged outside the carrier <NUM>. In some embodiments, the plunger <NUM> is arranged outside the carrier <NUM> and overlapped with the injector 105b from a top view. In some embodiments, as shown in <FIG>, the carrier <NUM> rotates and moves the first molding device <NUM>-<NUM> to a position adjacent to the injection station <NUM> and the plunger <NUM>. In some embodiments, as shown in <FIG>, the first molding device <NUM>-<NUM> is then conveyed from the carrier <NUM> to the injection station <NUM> by a conveying mechanism such as rollers, conveying belts or the like.

After the conveying of the first molding device <NUM>-<NUM> from the carrier <NUM> to the injection station <NUM>, the first molding device <NUM>-<NUM>, the plunger <NUM> and the injection station <NUM> is in configuration similar to the injection molding system <NUM> as described above or illustrated in <FIG>. The first molding devices <NUM>-<NUM> is moved from the carrier <NUM> to the injection station <NUM>, and then placed on the platform 105a of the injection station <NUM>, and then the injection molding method M10 as described above or shown in <FIG> is performed for the first molding device <NUM>-<NUM>. After the accomplishment of the injection molding method M10, the first molding device <NUM>-<NUM> is moved out of the injection station <NUM> and conveyed back to the carrier <NUM> as shown in <FIG>.

After the first molding device <NUM>-<NUM> is conveyed back to the carrier <NUM>, the first molding device <NUM>-<NUM> is moved away from the injection station <NUM> by the rotation of the carrier <NUM>. Simultaneously, another molding device <NUM> such as the second molding device <NUM>-<NUM> is moved toward the injection station <NUM> by the rotation of the carrier <NUM>.

<FIG> are schematic top views illustrating the injection molding systems <NUM> of the method M20 in accordance with some embodiments of the present disclosure. In some embodiments as shown in <FIG>, the injection station <NUM> is arranged outside the conveying belt <NUM>. In some embodiments, the plunger <NUM> is arranged outside the carrier <NUM> and overlapped with the injector 105b from a top view. In some embodiments as shown in <FIG>, the conveying belt <NUM> conveys the first molding device <NUM>-<NUM> and moves the first molding device <NUM>-<NUM> to a position adjacent to the injection station <NUM> and the plunger <NUM>. In some embodiments, as shown in <FIG>, the first molding device <NUM>-<NUM> is conveyed from the conveying belt <NUM> to the injection station <NUM> by a conveying mechanism such as rollers, conveying belts or the like.

After the conveying of the first molding device <NUM>-<NUM> from the conveying belt <NUM> to the injection station <NUM>, the first molding device <NUM>-<NUM>, the plunger <NUM> and the injection station <NUM> is in configuration similar to the injection molding system <NUM> as described above or illustrated in <FIG> and <FIG>. The first molding device <NUM>-<NUM> is moved out from the conveying belt <NUM> and then placed on the platform 105a of the injection station <NUM>, and then the injection molding method M10 as described above or shown in <FIG> is performed to the first molding device <NUM>-<NUM>. After the accomplishment of the injection molding method M10, the first molding device <NUM>-<NUM> is moved out of the injection station <NUM> and conveyed back to the conveying belt <NUM> as shown in <FIG>.

After the first molding device <NUM>-<NUM> is conveyed back to the conveying belt <NUM>, the first molding device <NUM>-<NUM> is moved away from the injection station <NUM> by the movement of the conveying belt <NUM>. Simultaneously, another molding device <NUM> such as the second molding device <NUM>-<NUM> is moved toward the conveying belt <NUM> by the movement of the conveying belt <NUM>. In some embodiments as shown in <FIG>, the molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> are linearly movable by the conveying belt <NUM>.

<FIG> are schematic top views illustrating the injection molding systems <NUM>, <NUM> of the method M20 in accordance with some embodiments of the present disclosure. In some embodiments as shown in <FIG>, each of the molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and the corresponding plunger <NUM> are configured as a molding module <NUM>. In other words, the molding device <NUM> and the corresponding plunger <NUM> are moved together into the injection station <NUM>. In some embodiments, the molding device <NUM> is disposed above and overlapped with the plunger <NUM> from a top view before moving into the injection station <NUM>. In some embodiments, the second opening <NUM> of the first mold base 101d is overlapped with the rod 104b of the corresponding plunger <NUM> from a top view. In some embodiments, each of the plunger <NUM> is moved together with the corresponding molding devices <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> by the rotation of the carrier <NUM>.

In some embodiments, as shown in <FIG>, the injection station <NUM> is disposed across the carrier <NUM>, and several molding modules <NUM> are arranged in the carrier <NUM>. In some embodiments, one of the molding modules <NUM> is disposed in the injection station <NUM>. The molding modules <NUM> are conveyed into the injection station <NUM> one by one by the rotation of the carrier <NUM>. For example, the first molding device <NUM>-<NUM> and the corresponding plunger <NUM> is moved and placed in the injection station <NUM>, and then the injection molding method M10 as described above or shown in <FIG> is performed to the molding module <NUM> including the first molding device <NUM>-<NUM>.

Similarly, in some embodiments, as shown in <FIG>, the injection station <NUM> is disposed across the conveying belt <NUM>, and several molding modules <NUM> are arranged on the conveying belt <NUM>. In some embodiments, one of the molding modules <NUM> is disposed in the injection station <NUM>. The molding modules <NUM> are conveyed into the injection station <NUM> one by one by the movement of the conveying belt <NUM>. For example, the first molding devices <NUM>-<NUM> and the corresponding plunger <NUM> is moved out from the conveying belt <NUM> and then placed on the platform 105a of the injection station <NUM>, and then the injection molding method M10 as described above or shown in <FIG> is performed for the molding module <NUM> including the first molding device <NUM>-<NUM>.

In some embodiments, as shown in <FIG>, the injection station <NUM> is arranged outside the carrier <NUM>. In some embodiments, the carrier <NUM> rotates and moves the molding module <NUM> including the first molding device <NUM>-<NUM> to a position adjacent to the injection station <NUM>. As shown in <FIG>, the molding module <NUM> including the first molding device <NUM>-<NUM> is conveyed from the carrier <NUM> to the injection station <NUM> by a conveying mechanism such as rollers, conveying belts or the like. The molding module <NUM> including the first molding device <NUM>-<NUM> is moved out from the carrier <NUM>, and then placed on the platform 105a of the injection station <NUM>, and then the injection molding method M10 as described above or shown in <FIG> is performed for the molding module <NUM> including the first molding device <NUM>-<NUM>. After the accomplishment of the injection molding method M10, the molding module <NUM> including the first molding device <NUM>-<NUM> is moved out of the injection station <NUM> and conveyed back to the carrier <NUM>, as shown in <FIG>.

In some embodiments, as shown in <FIG>, the injection station <NUM> is arranged outside the conveying belt <NUM>. In some embodiments, the conveying belt <NUM> moves the molding module <NUM> including the first molding device <NUM>-<NUM> to a position adjacent to the injection station <NUM>. As shown in <FIG>, the molding module <NUM> including the first molding device <NUM>-<NUM> is conveyed from the conveying belt <NUM> to the injection station <NUM> by a conveying mechanism such as rollers, conveying belts or the like. The molding module <NUM> including the first molding device <NUM>-<NUM> is moved out from the conveying belt <NUM>, and then placed on the platform 105a of the injection station <NUM>, and then the injection molding method M10 as described above or shown in <FIG> is performed for the molding module <NUM> including the first molding device <NUM>-<NUM>. After the accomplishment of the injection molding method M10, the molding module <NUM> including the first molding device <NUM>-<NUM> is moved out of the injection station <NUM> and conveyed back to the conveying belt <NUM>, as shown in <FIG>.

An aspect of this disclosure relates to an injection molding system includes an injection station, a molding device, and a plunger. The injection station includes a platform and an injector disposed over the platform, wherein the platform includes a first opening extending through the platform. The molding device is disposed between the platform and the injector and over the first opening, wherein the molding device includes a mold cavity and a clamping unit for clamping the molding device. The plunger disposed under the platform, wherein the plunger includes a base and a rod, the rod is extendable through the first opening toward the molding device and retractable toward the base.

In some embodiments, the plunger is movable relative to the injection station. In some embodiments, the rod is vertically aligned with the injector. In some embodiments, the mold cavity is defined by a first mold base and a second mold base disposed over and corresponding to the first mold base, wherein the molding device further includes a first mold disposed in the first mold base and a second mold disposed over and corresponding to the first mold. In some embodiments, the first mold base includes a second opening configured to receive at least a portion of the rod, and the second opening is overlapped with the first opening from a top view. In some embodiments, the rod is extendable through the second opening. In some embodiments, the injection molding system further includes a locking device configured to lock the molding device on the platform, wherein the locking device includes a first locking element disposed on the molding device and a second locking element disposed on the platform and corresponding to the first locking element.

An aspect of this disclosure relates to an injection molding method. The method includes providing an injection station including a platform and an injector disposed over the platform, wherein the platform includes a first opening extending through the platform; conveying a molding device to the injection station and disposing the molding device between the injector and the platform, wherein the molding device includes a first mold, a second mold over the first mold and a mold cavity defined by the first mold and the second mold; disposing a plunger under the molding device and the platform, wherein the plunger includes a base and a rod extendable toward the molding device and retractable toward the base; moving the injector towards the molding device to communicate with the mold cavity; applying a plunging force on the molding device by extending the rod through the first opening towards the molding device; and injecting a molding material from the injector into the mold cavity.

In some embodiments, the method further includes locking the molding device on the platform before injection; unlock the molding device from the platform after injection; withdrawing the injector from the molding device after the injection; retracting the rod towards the base after the injection; moving the plunger away from the injection station after the retraction; and conveying the molding device away from the injection station after the withdrawal of the injector and the retraction of the rod.

In some embodiments, the molding device and the plunger are conveyed into the injection station simultaneously. In some embodiments, the rod contacts the molding device during the application of the plunging force. In some embodiments, the method further includes aligning the injector with the rod before and during injecting the molding material. In some embodiments, the plunger is fixedly disposed under the molding device and the first opening. In some embodiments, the method further includes providing a clamping force to clamp the first mold and the second mold during the conveying of the molding device and the injection of the molding material.

An aspect of this disclosure relates to an injection molding method. The method includes providing a carrier, wherein a first molding device and a second molding device are held by the carrier; providing an injection station including a platform and an injector disposed over the platform, wherein the platform includes a first opening extending through the platform; providing a plunger disposed under the platform, wherein the plunger includes a base and a rod extendable from and retractable toward the base; moving the first molding device into the injection station and disposing the first molding device between the injector and the platform; providing a plunging force to the first molding device by extending the rod through the first opening to contact the first molding device; injecting a molding material from the injector into the first molding device; withdrawing the injector and the rod from the first molding device after injection; moving the first molding device from the injection station; and moving the second molding device into the injection station and disposing the second molding device between the injector and the platform.

In some embodiments, the method further includes providing the plunging force to the second molding device by extending the rod through the first opening to contact the second molding device; injecting the molding material from the injector into the second molding device; withdrawing the injector and the rod from the second molding device after the injection; moving the second molding device away from the injection station.

In some embodiments, the platform is fixedly disposed under the carrier, and the injector is fixedly disposed over the carrier and overlapped with the first opening from a top view. In some embodiments, the first molding device and the second molding device are moved into the injection station by rotation of the carrier. In some embodiments, the method further includes moving the plunger to dispose under the carrier and the injection station while the carrier is stationary, or moving the carrier to dispose the plunger under the carrier while the plunger is stationary. In some embodiments, the injection station and the plunger are movable, and the carrier is stationary.

Claim 1:
An injection molding system (<NUM>), including:
an injection station (<NUM>) including a platform (105a) and an injector (105b) disposed over the platform (105a);
a molding device (<NUM>) disposed between the platform (105a) and the injector (105b) and over the first opening (105d), wherein the molding device (<NUM>) includes a first mold base (101d), a second mold base (101c) disposed over and corresponding to the first mold base (101d), a mold cavity (101e) defined by the first mold base (101d) and the second mold base (101c), and a clamping unit (<NUM>) coupled the second mold base (101c) with the first mold base (101d) and configured for clamping the molding device (<NUM>), wherein the molding device (<NUM>) and the clamping unit (<NUM>) are movable away from the injection station (<NUM>); and
a plunger (<NUM>) disposed under the platform (105a) and movable away from the injection station (<NUM>),
wherein the platform (105a) includes a first opening (105d) extending through the platform (105a), and the plunger (<NUM>) includes a base (104a) and a rod (104b), the rod (104b) is extendable through the first opening (105d) toward the molding device (<NUM>) and retractable toward the base (104a).