Patent Description:
The present invention is related to an article and a method of manufacturing the same, and, in particular, to an article including a foamed member and a core and a method of manufacturing the same.

Article including a foamed member and a core has many advantages, such as high strength, low weight, impact resistance, thermal insulation, and others. The article can be made by adhere the foamed member and the core or interlock the two with each other, as such, at least an entire surface of the core maybe exposed. Therefore, there is a need for improvements to structures of the article including the foamed member and the core and the method for making the article.

<CIT> discloses a seat incorporating an insert or inserts intermediate its upper and lower surfaces. A seat insert adapted for the support of the users buttocks and/or upper thighs conforms to the contours of the user's body over a period of time, has certain "rebound" properties, and features an area adapted to underlie the perineum of a user seated on the seat, which area is softer than the rest of the seat insert either by virtue of an included gap in the seat insert or by virtue of a softer material filling said gap. Alternatively, a perineal insert of softer material may be used without the seat insert described. In either case, the aforesaid inserts are preferably completely encapsulated and enclosed by the foam materials making up the seat, which can be accomplished by molding the seat around the insert(s). These innovations enable the seat to be molded with various internal density control zones and to otherwise provide a more comfortable seat to the user with enhanced abilities to conform to the user's body and enhanced springiness, while limiting pressure on the user's perineum.

<CIT> discloses an architectural flooring plate spaced from a concrete bottom and a method of manufacturing the same. In the flooring plate of the invention, the upper plate, the foaming resin and the coring member having the plurality of circulation holes are sequentially injected into the receiving groove formed in the lower mold and the foaming resin is foamed at a room temperature so that the foamed body is integrally formed with the upper panel and the coring member, and the border is integrally formed with the body at the outside of the upper panel. The upper panel and the coring member are naturally fixed to the body as the foaming resin is foamed and dried so as to integrally form the flooring plate thereby simplifying a manufacturing process thereof. Attaching the additional aluminum sheet is not necessary to reduce the overall manufacturing cost and enhance the competitiveness.

<CIT> discloses a cushion body having a core material formed by a melamine resin foam body, and a surface layer material formed by a polyurethane resin foam body in which an expandable graphite is dispersed, and covering a periphery of the core material. A through hole extending along a thickness direction of the cushion body is formed at a predetermined position of the core material. A surface layer material fills the through hole, and the core material and the surface layer material are integrally formed. The cushion body increases a lightweight property of the cushion body by the core material formed by the melamine resin foam body, increases a fire retardant property of the cushion body by the expandable graphite, and increases cushioning and durability properties of the cushion body by the polyurethane resin foam body.

One purpose of the present invention is to provide an article and a method of manufacturing the same.

According to the invention, an article is disclosed according to claim <NUM>.

According to the invention, a method of manufacturing an article is disclosed according to claim <NUM>.

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> illustrates a schematic view of an article according to one embodiment of the present disclosure. <FIG> and <FIG> are schematic diagrams illustrating a core of the article according to one embodiment of the present disclosure. The core of the article can be in various configurations as shown in any of <FIG> are schematic cross-sectional views taken along a line II-II' in <FIG> and illustrate various configuration of an article according to one embodiment of the present disclosure. Referring to <FIG> and <FIG>, an article <NUM> includes a foamed member <NUM> including a polymeric material and a core <NUM> embedded in the foamed member <NUM>. The core <NUM> improves a strength of the article <NUM>. The shape of the core <NUM> and the foamed member <NUM> may corresponding to each other, can be, but are not limited to, round, oval, rectangular, square or other desired shape from a top view. In some embodiments, the article <NUM> is a part of a footwear or a semi-product of a footwear. In some embodiments, the article <NUM> is an outsole of the footwear. In some embodiments, the article <NUM> is a midsole of the footwear. In some embodiments, a thickness of the article <NUM> is equal to or greater than <NUM>. In some embodiments, the thickness of the article <NUM> is equal to or greater than <NUM>.

In some embodiments, the foamed member <NUM> includes a polymeric material such as ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethanes (TPU), thermoplastic polyester elastomer (TPEE) or the like. In some embodiments, the foamed member <NUM> includes a recyclable material. In some embodiments, a thickness of a periphery of the foamed member <NUM> is equal to or greater than <NUM>. In some embodiments, the thickness of the periphery of the foamed member <NUM> is equal to or greater than <NUM>. In some embodiments, the foamed member <NUM> further includes a blowing agent. In some embodiments, the blowing agent can be any type of chemical or physical blowing agent known to those of ordinary skill in the art. In some embodiments, the blowing agent is a supercritical fluid. The supercritical fluid may include inert gas such as carbon dioxide or nitrogen in supercritical state. In some embodiments, the foamed member <NUM> is made from a molding material including a polymeric material and a blowing agent. In some embodiments, the article <NUM> is free from adhesive.

According to the invention, the core <NUM> includes a first surface <NUM>, a second surface <NUM> opposite to the first surface <NUM>, and a sidewall <NUM> between the first surface <NUM> and the second surface <NUM>. According to the invention, the foamed member <NUM> covers at least a portion of the first surface <NUM>, and covers the entire sidewall <NUM> and the entire second surface <NUM>. In some embodiments, the foamed member <NUM> contacts at least a portion of the first surface <NUM>, and contacts the entire sidewall <NUM> and the entire second surface <NUM>. According to the invention, a portion of the first surface <NUM> is exposed through the foamed member <NUM>. According to the invention, a mark <NUM> is disposed at and indented into the foamed member <NUM>. According to the invention, a portion of the first surface <NUM> is exposed through the mark <NUM>. In some embodiments, the mark <NUM> and the core <NUM> are overlapped from a top view.

In some examples, not according to the invention, the article <NUM> is free of the mark <NUM>, and the core <NUM> is enclosed by the foamed member <NUM>. The foamed member <NUM> contacts the entire first surface <NUM>, the entire sidewall <NUM>, and the entire second surface <NUM>.

In some embodiments, the core <NUM> includes a polymeric material such as ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethanes (TPU), thermoplastic polyester elastomer (TPEE) or the like. In some embodiments, the core <NUM> is a non-foamable piece. In some embodiments, the core <NUM> includes a recyclable material. Alternatively, in some embodiments, the core <NUM> is a foamed piece. In some embodiments, the foamed piece includes a polymeric material and a blowing agent. In some embodiments, a stiffness of the non-foamable piece is greater than a stiffness of the foamed piece. In some embodiments, the core <NUM> and the foamed member <NUM> include the same material.

In order to enhance the bonding strength between the core <NUM> and the foamed member <NUM>, in some embodiments, a surface area of the core <NUM> is increased by forming a pattern on the first surface <NUM> and/or the second surface <NUM>, and at least a portion of the foamed member <NUM> is conformal to the pattern. In some embodiments, the properties of the core <NUM> is affected by the pattern. The pattern may distribute across the core <NUM>, and may not be limited to any particular type, as long as the properties of core <NUM> meet actual needs. In some embodiments, at least one of the first surface <NUM>, the second surface <NUM>, and the sidewall <NUM> is a roughened surface. In some embodiments, the core <NUM> has a Young's modulus ranging between <NUM> and <NUM>/mm<NUM>.

In some embodiments, referring to <FIG>, the core <NUM> includes two or more pieces. In some embodiments, the core <NUM> includes a first layer <NUM> and a second layer <NUM> disposed over the first layer <NUM>. Alternatively, the first <NUM> is disposed over the second layer <NUM> in some embodiments. In some embodiments, the first layer <NUM> attaches to the second layer <NUM>. In some embodiments, the first layer <NUM> is a non-foamable piece, and the second layer <NUM> is a foamed piece. In some embodiments, the first layer <NUM> and the second layer <NUM> includes same or different materials. In some embodiments, the first layer <NUM> directly bonds to the second layer <NUM>. In some embodiments, an adhesive is disposed between the first layer <NUM> and the second layer <NUM> to bond the first layer <NUM> with the second layer <NUM>.

In some embodiments, referring to <FIG> and <FIG>, the pattern is a through hole <NUM> extending between the first surface <NUM> and the second surface <NUM>. In some embodiments, a portion of the foamed member <NUM> is disposed within the through hole <NUM>. In some embodiments, a plurality of the through holes <NUM> are extending between the first surface <NUM> and the second surface <NUM>. In some embodiments, the through holes <NUM> are disposed throughout the core <NUM>. In some embodiments, a density, sizes and the shapes of the through holes <NUM> are not limited as long as the properties of the core <NUM> meet the actual needs.

In some embodiments, referring to <FIG> and <FIG>, the pattern is a recess <NUM> indented into the core <NUM> and disposed at the first surface <NUM>. In some embodiments, a portion of the foamed member <NUM> is disposed within the recess <NUM>. In some embodiments, a plurality of recesses <NUM> are disposed at the first surface <NUM>, the second surface <NUM> and/or the sidewall <NUM> of the core <NUM>. In some embodiments, a density, sizes, depths and the shapes of the recesses <NUM> are not limited as long as the properties of the core <NUM> meet the actual needs.

In some embodiments, referring to <FIG> and <FIG>, the pattern is protrusion <NUM> protruded from the first surface <NUM>. In some embodiments, the foamed member <NUM> surrounds the protrusion <NUM>. In some embodiments, a plurality of protrusions <NUM> are disposed at the first surface <NUM>, the second surface <NUM> and/or the sidewall <NUM> of the core <NUM>. In some embodiments, a density, sizes, heights and the shapes of the protrusions <NUM> are not limited as long as the properties of the core <NUM> meet the actual needs.

<FIG> is a schematic cross-sectional view of an article in accordance with some embodiments of the present disclosure. In some embodiments, referring to <FIG>, a component <NUM> is disposed over the core <NUM> and the foamed member <NUM>. In some embodiments, the component <NUM> is attached to and disposed over the foamed member <NUM>. In some embodiments, a portion of the foamed member <NUM> is disposed between the component <NUM> and the core <NUM>, so that the core <NUM> is not in contact with the component <NUM>. In some embodiments, the component <NUM> is adjacent to the core <NUM>. In some embodiments, the first surface <NUM> of the core <NUM> faces the component <NUM>. In some embodiments, the component <NUM> is an insole, a footwear upper or any other suitable component of the footwear.

<FIG> is a flowchart showing a method <NUM> of manufacturing an article in accordance with some embodiments of the present disclosure. The method <NUM> includes several operations: (<NUM>) providing a molding device, wherein the molding device includes a first mold, a second mold corresponding to the first mold, the first mold includes an inner wall and a supporting member protruded from the inner wall; (<NUM>) disposing a core on the supporting member; (<NUM>) disposing the second mold over the first mold to form a mold cavity defined by the first mold and the second mold, wherein the core is disposed within the mold cavity; (<NUM>) injecting a first material into the mold cavity; and (<NUM>) foaming the first material to form a first foamed member, wherein at least a portion of the first foamed member is in contact with the core.

In order to illustrate concepts and the 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. The various operations and the thus formed articles of the injection molding method can be in various configurations as shown in any of <FIG>, <FIG>, <FIG> and <FIG>. <FIG> is a schematic cross-sectional view illustrating an article <NUM> manufactured by the method <NUM> in accordance with some embodiments of the present disclosure.

In some embodiments, an injection-molding system <NUM> of the operation <NUM> of the method <NUM> in accordance with some embodiments of the present disclosure is illustrated in <FIG>. According to the invention, the method <NUM> of manufacturing an article <NUM> includes operation <NUM>, which includes providing a molding device <NUM>, wherein the molding device <NUM> includes a first mold <NUM>, a second mold <NUM> corresponding to the first mold <NUM>. In some embodiments, the first mold <NUM> is a lower mold, and the second mold <NUM> is an upper mold. In some embodiments, the molding device <NUM> includes a mold base <NUM> adjacent to the first mold <NUM> and the second mold <NUM>. In some embodiments, the mold base <NUM> attaches to the first mold <NUM>. In some embodiments, the molding device <NUM> is provided or received as shown in <FIG>. In some embodiments, the molding device <NUM> is configured to forming the article <NUM>.

In some embodiments, the first mold <NUM> and the second mold <NUM> are separated from each other during operation <NUM>. In some embodiments, the first mold <NUM> and the second mold <NUM> are complementary with and separable from each other. In some embodiments, the first mold <NUM> and the second mold <NUM> are complementary with each other in order to define a mold cavity (not shown).

In some embodiments, the first mold <NUM> defines a lower mold cavity <NUM> and the second mold <NUM> defines an upper mold cavity <NUM>. According to the invention, the first mold <NUM> includes an inner wall <NUM> and a supporting member <NUM> protruded from the inner wall <NUM>. In some embodiments, the inner wall <NUM> of the first mold <NUM> is curved.

In some embodiments, at least one feeding port <NUM> is disposed at the molding device <NUM>. In some embodiments, the feeding port <NUM> is disposed at the first mold <NUM> or the second mold <NUM>. In some embodiments, the feeding port <NUM> is communicable with the upper mold cavity <NUM> or the lower mold cavity <NUM>. <FIG> illustrates only one feeding ports <NUM> is included in one mold for clarity and simplicity, but such example is intended to be illustrative only, and is not intended to be limiting to the embodiments. A person ordinarily skilled in the art would readily understand that one mold may include one or more feeding port <NUM> communicable with the upper mold cavity <NUM> or the lower mold cavity <NUM>.

The feeding port <NUM> is configured to receive a molding material (not shown) into the upper mold cavity <NUM> and/or the lower mold cavity <NUM>. In some embodiments, several feeding ports <NUM> are disposed at the molding device <NUM>. The molding material can be transported into the molding device <NUM> through the feeding port <NUM>. In some embodiments, the molding material is injected into the upper mold cavity <NUM> and the lower mold cavity <NUM> and then the foamed member <NUM> is formed in the upper mold cavity <NUM> and the lower mold cavity <NUM> after a period of time. In some embodiments, the feeding port <NUM> is disposed at the first mold <NUM>. In some embodiments, the feeding port <NUM> can be configured at a sidewall of the first mold <NUM> or any other suitable positions as long as the feeding port <NUM> is communicable with the lower mold cavity <NUM>. In some embodiments, instead of configuring the feeding port <NUM> at the first mold <NUM>, the first feeding port <NUM> can be configured at the second mold <NUM> for accessing the upper mold cavity <NUM>.

In some embodiments, a feeding opening <NUM> is in connection with the feeding port <NUM>. In some embodiments, the feeding opening <NUM> is configured to transport the molding material from the feeding port into the molding device <NUM>. In some embodiments, the feeding opening <NUM> is disposed at the inner wall <NUM> of the first mold <NUM> and configured to transport the molding material from the feeding port <NUM> into the lower mold cavity <NUM>. In some embodiments, the feeding opening <NUM> is disposed at the inner sidewall <NUM> of the first mold <NUM>. In some embodiments, the feeding opening <NUM> is disposed at the inner bottom wall <NUM> of the first mold <NUM>. In some embodiments, the feeding opening <NUM> is disposed at the inner wall <NUM> of the second mold <NUM>. In some embodiments, the feeding opening <NUM> is disposed adjacent to and separated from the supporting member <NUM>. In some embodiments, the feeding port <NUM> is in communication with a plurality of feeding openings <NUM>. In some embodiments, the plurality of the feeding openings <NUM> are respectively connected with the feeding port <NUM>. In some embodiments, the feeding openings <NUM> can have different widths or diameters. The locations of the feeding openings <NUM> are not particularly limited, they can be disposed at different regions of the inner wall <NUM> of the first mold <NUM> and the inner wall <NUM> of the second mold <NUM>. In some embodiments, an end at which the feeding port <NUM> connects with the upper mold cavity <NUM> and/or the lower mold cavity <NUM> have a plurality of guiding channels <NUM>, wherein each guiding channel <NUM> is connected to a corresponding feeding opening <NUM> and the feeding port <NUM>.

In some embodiments, the mold base <NUM> includes openings <NUM>. Each of the openings <NUM> extends through the mold base <NUM>. The mold base <NUM> may be mounted on the first mold <NUM> or the second mold <NUM> by a screw, a clamp, a fastening means or the like. In some embodiments, the material of the mold base <NUM> is same as the material of the first mold <NUM>. In some embodiments, a height H1 of the mold base <NUM> is greater than or equal to a height H2 of the first mold <NUM> or the second mold <NUM>.

In some embodiments, the molding devices <NUM> further includes one or more pressure-regulating systems <NUM>. In some embodiments, and a junction point <NUM> is in connection with the lower mold cavity <NUM> and/or the upper mold cavity <NUM>. In some embodiments, a plurality of junction points <NUM> are in connection with the upper mold cavity <NUM> and the lower mold cavity <NUM>. In some embodiments, the junction points <NUM> are configured to allow a fluid or gas to enter into or exit from the molding device <NUM>. The location, shape and number of the junction points <NUM> are not particularly limited, and may be adjusted depending on the needs. In some embodiments, each of the junction points <NUM> is a hole.

The pressure-regulating system <NUM> may include a first gas conduit <NUM>, a second gas conduit <NUM>, a gas source <NUM>, a first valve <NUM>, a second valve <NUM>, and a pressure-sensing unit <NUM>. In some embodiments, one end of the first gas conduit <NUM> is coupled to the junction point <NUM>, and the other end of the first gas conduit <NUM> is coupled to the gas source <NUM>. In some embodiments, the gas source <NUM> is configured to supply a fluid or gas, in which a suitable fluid or gas may be supplied depending on the needs; for example, the fluid or gas may be air, inert gas, etc., but the present invention is not limited thereto. In some embodiments, one end of the first gas conduit <NUM> is coupled to the junction point <NUM>.

In some embodiments, the junction points <NUM> are configured to supply gas or discharge gas. The first valve <NUM> is disposed at the first gas conduit <NUM> and is configured to control whether the gas from the gas source <NUM> enters the lower mold cavity <NUM> and/or the upper mold cavity <NUM> through the first gas conduit <NUM> and the junction point <NUM>. In some embodiments, when the first valve <NUM> is open and the second valve <NUM> is closed, the fluid or gas is supplied to the lower mold cavity <NUM> and/or the upper mold cavity <NUM>; when the first valve <NUM> is closed and the second valve <NUM> is open, at least a portion of the fluid or gas in the lower mold cavity <NUM> and/or the upper mold cavity <NUM> is discharged.

In some embodiments, the second gas conduit <NUM> is coupled to the junction point <NUM>. The second valve <NUM> is disposed at the second gas conduit <NUM> and is configured to control whether the gas from the lower mold cavity <NUM> or the upper mold cavity <NUM> is discharged valve the junction point <NUM> through the second gas conduit <NUM>. In some embodiments, the second gas conduit <NUM> is coupled to the junction point <NUM>.

In some embodiments, one end of the second gas conduit <NUM> is in communication with a space with a pressure lower than the pressure in the lower mold cavity <NUM> or the upper mold cavity <NUM>; for example, an external environment or a negative pressure space; however, the present invention is not limited thereto. In some embodiments, the first valve <NUM> and the second valve <NUM> are not simultaneously open.

The pressure-sensing unit <NUM> is configured to sense the pressure in the lower mold cavity <NUM> or the upper mold cavity <NUM>. The pressure-sensing unit <NUM> is not limited to any particular type, as long as it can sense the pressure and provide pressure information after sensing the pressure in the lower mold cavity <NUM> or the upper mold cavity <NUM>. The pressure-regulating system <NUM> changes the condition at which the gas exits from/enters into the lower mold cavity <NUM> or the upper mold cavity <NUM> in accordance with the pressure information, so as to adjust the pressure in the lower mold cavity <NUM> or the upper mold cavity <NUM>, in such a manner that the composite thus obtained has the desired predetermined shape and property.

In some embodiments, the pressure-sensing unit <NUM> is disposed in the lower mold cavity, the upper mold cavity <NUM>, the first gas conduit <NUM> or the second gas conduit <NUM>. In some embodiments, the pressure-sensing unit <NUM> is disposed in the lower mold cavity <NUM> and the upper mold cavity <NUM> and is away from the feeding openings <NUM>. In some embodiments, the pressure-regulating system <NUM> has a plurality of pressure-sensing units <NUM>. The number and location of the plurality of pressure-sensing units <NUM> are not particularly limited, for example, they can be arranged at the inner wall <NUM> of the first mold <NUM> and the inner wall <NUM> of the second mold <NUM> and spaced from each other, and/or anywhere in the first gas conduit <NUM>, and/or anywhere in the second gas conduit <NUM>; however, the present invention is not limited thereto.

In some embodiments, the supporting member <NUM> is configured to support the core <NUM> and prevent the core <NUM> from in contact with the inner wall <NUM> of the first mold <NUM>. The core <NUM> may dispose on the supporting member <NUM>, and the molding material subsequently filled into the molding device <NUM> may in contact with the first surface <NUM>, the second surface <NUM> and the sidewall <NUM> of the core <NUM>. In some embodiments, a surface area of a top surface of the supporting member <NUM> is smaller than that of the first surface <NUM> of the core <NUM>. In some embodiments, the supporting member <NUM> and the feeding openings <NUM> are disposed at the inner wall <NUM> of the first mold <NUM>. The supporting member <NUM>, the feeding openings <NUM> and the junction points <NUM> are separated from each other.

In some embodiments, the supporting member <NUM> includes a plurality of supporting units <NUM>, <NUM>, <NUM> protruded from the inner wall <NUM>. The supporting units <NUM>, <NUM>, <NUM> are separated from each other. The locations and number of the supporting units <NUM>, <NUM>, <NUM> are not particularly limited, and may be adjusted depending on the needs, such as disposed them at different regions of the inner wall <NUM> of the first mold <NUM>. In some embodiments, the supporting units <NUM>, <NUM>, <NUM> are disposed at and protruded from the inner bottom wall <NUM> of the first mold <NUM>. In some embodiments, at least two of the supporting unit <NUM>, <NUM>, <NUM> are disposed at the opposite sides of the inner wall <NUM> of the first mold <NUM>. In some embodiments, the number of the junction points <NUM> is greater than the number of the supporting units <NUM>, <NUM>, <NUM>. The heights of each of the supporting units <NUM>, <NUM>, <NUM> may be same or different, as long as the core <NUM> may be disposed on the supporting units <NUM>, <NUM>, <NUM>. In some embodiments, the heights of each of the supporting units <NUM>, <NUM>, <NUM> are the same.

In some embodiments, each of the supporting units <NUM>, <NUM>, <NUM> are disposed adjacent to the corresponding feeding openings <NUM> from a cross-section view. In some embodiments, each of the supporting units <NUM>, <NUM>, <NUM> are disposed adjacent to the corresponding junction points <NUM> from a cross-section view. In some embodiments, one of the supporting units <NUM>, <NUM>, <NUM> is disposed between the corresponding feeding opening <NUM> and the corresponding junction point <NUM>. In some embodiments, one of the supporting units <NUM>, <NUM>, <NUM> is disposed adjacent to the corresponding feeding opening <NUM> and the corresponding junction point <NUM>. In some embodiments, one of the feeding opening <NUM> is disposed between the corresponding junction point <NUM> and the corresponding supporting unit <NUM>.

In some embodiments, in order to maintain the temperature difference between the discharging channel <NUM> and the molding device <NUM>, the injection molding system <NUM> further includes an insulator <NUM> disposed between the discharging channel <NUM> and the molding device <NUM>. In some embodiments, the insulator <NUM> is disposed between the discharging channel <NUM> and the mold base <NUM>. In some embodiments, the insulator <NUM> is disposed on the mold base <NUM>. In some embodiments, the insulator <NUM> is disposed between the outlet <NUM> and the feeding port <NUM>.

The discharging channel <NUM> may extend into the insulator <NUM> and is thereby partially surrounded by the insulator <NUM>. In some embodiments, the insulator <NUM> includes openings <NUM> configured to receive the discharging channel <NUM>. The openings <NUM> of the insulator <NUM> are aligned to the openings <NUM> of the mold base <NUM> and the feeding port <NUM>. The openings <NUM> extends through the insulator <NUM>. The insulator <NUM> may be mounted on the mold base <NUM>, such as by a screw. The insulator <NUM> may include a non-thermally conductive material, such as a fiber glass. The insulator <NUM> may be comprised entirely of non-metal materials. In some embodiments, the insulator <NUM> has a melting point substantially greater a temperature of the mixture flowing through the discharging channel <NUM>. In some embodiments, the melting point of the insulator <NUM> is substantially greater than <NUM>.

<FIG> are schematic top views of a portion of an injection molding system <NUM> of the operation <NUM> of the method <NUM> in accordance with some embodiments of the present disclosure. The size and shape of each of the portion may be same as or different from each other, may be, but are not limited to, round, oval, rectangular, square, curved, strip or other desired shape from a top view. In some embodiments, referring to <FIG>, shapes of the supporting units <NUM>, <NUM>, <NUM> are similar to each other. In some embodiments, each of the supporting units <NUM>, <NUM>, <NUM> is a strip from a top view. Further, a distance D1 between the supporting unit <NUM> and the support unit <NUM> and a distance D2 between supporting unit <NUM> and the support unit <NUM> may be same or different. In some embodiments, the distance D1 is equal to the distance D2. In some embodiments, the distance D1 is different from the distance D2. A length L1 of the supporting unit <NUM>, a length L2 of the supporting unit <NUM>, and a length L3 of the supporting unit <NUM> may be same or different from each other. The lengths L1, L2, L3 are not limited, as long as the core <NUM> may dispose on the support member <NUM>.

In some embodiments, referring to <FIG>, shapes of the supporting units <NUM>, <NUM>, <NUM> are different. Is some embodiments, the supporting unit <NUM> is disposed between the supporting unit <NUM> and supporting unit <NUM>. The shape of the supporting unit <NUM> is similar to that of the supporting unit <NUM>, and the shape of the supporting unit <NUM> is different from that of the supporting unit <NUM>. In some embodiments, the supporting units <NUM>, <NUM>, <NUM> are arranged in a row. In some embodiments, referring to <FIG>, the supporting units <NUM>, <NUM>, <NUM> are arranged in an arc. In some embodiments, referring to <FIG>, at least one of the supporting units <NUM>, <NUM>, <NUM> is in a shape of a curved. In some embodiments, at least one of the feeding openings <NUM> and one of the junction points <NUM> are disposed between the supporting unit <NUM> and the supporting unit <NUM>.

In some embodiments, the method <NUM> further includes providing an extruding system <NUM> configured to produce a molding material (not shown), and providing a discharging channel <NUM> communicable with the extruding system <NUM> and including an outlet <NUM> disposed distal to the extruding system <NUM> and configured to discharge the molding material. In some embodiments, the feeding port <NUM> of the molding device <NUM> is correspondingly engageable with the outlet <NUM>.

In some embodiments, the extruding system <NUM> and the discharging channel <NUM> are disposed adjacent to the feeding port <NUM> of the molding device <NUM>. The molding device <NUM> is configured to receive the molding material from the outlet <NUM> of the discharging channel <NUM>.

According to the invention, the method <NUM> of manufacturing an article includes operation <NUM>, which includes disposing a core <NUM> on the supporting member <NUM>. In some embodiments, referring to <FIG>, the core <NUM> is disposed on the supporting units <NUM>, <NUM>, <NUM>. In some embodiments, the core <NUM> is disposed is the lower mold cavity <NUM>. In some embodiments, the first surface <NUM> of the core <NUM> is in contact with the supporting unit <NUM>. In some embodiments, the supporting unit <NUM> is disposed between the core <NUM> and the inner wall <NUM> of the first mold <NUM>. Due to the supporting unit <NUM>, the core <NUM> disposed within the molding device <NUM> may not cover the feeding opening <NUM> and the junction point <NUM>.

In some embodiments, referring back to <FIG> and <FIG>, operation <NUM> includes disposing a first layer <NUM> of the core <NUM> over the supporting member <NUM>, and disposing a second layer <NUM> of the core <NUM> over the first layer <NUM>. In some embodiments, the method <NUM> includes disposing the first layer <NUM> and the second layer <NUM> into the molding device <NUM> one by one. In some embodiments, the second layer <NUM> attaches to the first layer <NUM>. In some embodiments, the method <NUM> includes bonding the first layer <NUM> to the second layer <NUM>, and disposing the first layer <NUM> and the second layer <NUM> into the molding device <NUM> at the same time.

In some embodiments, the method <NUM> of manufacturing an article includes operation <NUM>, which includes disposing the second mold <NUM> over the first mold <NUM> to form a mold cavity <NUM> defined by the first mold <NUM> and the second mold <NUM>, wherein the core <NUM> is disposed within the mold cavity <NUM>. In some embodiments, referring to <FIG>, the molding device <NUM> is in a closed configuration. In some embodiments, the mold cavity <NUM> is formed when the molding device <NUM> is in the closed configuration. In some embodiments, the first mold <NUM> is tightly engaged with the second mold <NUM> when the molding device <NUM> is closed.

In some embodiments, the method <NUM> includes engaging the outlet <NUM> with the feeding port <NUM> of the molding device <NUM>.

In some embodiments, at the beginning of operations <NUM> to <NUM>, referring back to <FIG> and <FIG>, the extruding system <NUM> and the discharging channel <NUM> are away from the molding device <NUM>. In some embodiments, before the engagement of the outlet <NUM> with the feeding port <NUM> of the molding device <NUM>, the discharging channel <NUM> are moved to a first position adjacent to the molding device <NUM>. In some embodiments, the discharging channels <NUM> are moved to the first position adjacent to the molding device <NUM>. At the first position, the discharging channel <NUM> are aligned with the opening <NUM> of the mold base <NUM> of the molding device <NUM>. In some embodiments, a distance between the outlet <NUM> and the outer surface of the mold base <NUM> is greater than <NUM>. In some embodiments, at the first position, the discharging channel <NUM> is aligned with the opening <NUM> of the insulator <NUM> and the opening <NUM> of the mold base <NUM>.

In some embodiments, referring to <FIG>, after the alignment of the discharging channel <NUM> with the openings <NUM>, the discharging channel <NUM> are moved toward the molding device <NUM> to be received by the openings <NUM> of the mold base <NUM>, and then the outlet <NUM> is docked to the feeding ports <NUM>. In some embodiments, the discharging channel <NUM> is moved toward the molding device <NUM> to be received by the openings <NUM> of the mold base <NUM>. In some embodiments, the discharging channel <NUM> is moved toward the molding device <NUM> to be received by the opening <NUM> of the insulator <NUM> and the openings <NUM> of the mold base <NUM>.

After the outlets <NUM> are docked to the feeding ports <NUM>, the outlet <NUM> and the feeding port <NUM> form flow paths of the molding material, such that the discharging channel <NUM> is communicable with the mold cavity <NUM> through the feeding port <NUM>. The outlets <NUM> must be tightly engaged with the feeding port <NUM> in order to prevent the molding material from leaking out of the molding device <NUM>.

In some embodiments, the method <NUM> includes securing the discharging channel <NUM> to the molding device <NUM>. In some embodiments, a force is provided by a support device <NUM> to prevent the separation of the extruding system <NUM> from the molding device <NUM>.

In some embodiments, when the extruding system <NUM> injects molding material into the molding device <NUM>, the molding device <NUM> may generate a reaction force opposite to an injection direction, and the reaction force may be transmitted to the discharging channel <NUM> and the extruding system <NUM>, so that the discharging channel <NUM> tend to separate from the molding device <NUM>. In some embodiments, the supporting device <NUM> provides support against the reaction force opposite to the injection direction.

In some embodiments, the discharging channel <NUM> is secured to the molding device <NUM> by engaging a first element <NUM> of the supporting device <NUM> relative to a second element <NUM> of the supporting device <NUM> to secure the discharging channel <NUM> with the molding device <NUM>, wherein the first element <NUM> protrudes from the extruding system <NUM>, and the second element <NUM> is disposed on the molding device <NUM>. In some embodiments, a force is provided by the supporting device <NUM> after the engagement to prevent the discharging channel <NUM> separating from the molding device <NUM>.

<FIG> is a schematic diagram of a portion of the injection molding system <NUM> according to one embodiment of the present disclosure. In some embodiments, referring to <FIG>, the supporting device <NUM> includes first and second elements <NUM>, <NUM> configured to engage with each other, wherein the first element <NUM> protrudes from the extruding system <NUM> or the discharging channel <NUM>, and the second element <NUM> is disposed on the molding devices <NUM>, but the disclosure is not limited thereto. In some embodiments, the first and second elements, <NUM>, <NUM> can be clamped to each other; for example, the second element <NUM> is configured to receive the first element <NUM>.

In some embodiments, the supporting device <NUM> is disposed adjacent to the mold cavity <NUM> of the molding device. In some embodiments, the first element <NUM> is disposed on the discharging channel <NUM>, and the second element <NUM> is disposed on the molding device <NUM>. In some embodiments, the second element <NUM> is disposed on the mold base <NUM> of the molding device <NUM>. In some embodiments, the first element <NUM> is a part of the extruding system <NUM> or the discharging channel <NUM>, while the second element <NUM> is a part of the molding device <NUM>. In some embodiments, the first element <NUM> is a part of the extruding system <NUM> and disposed adjacent to the discharging channels <NUM>, and the second element <NUM> is disposed above or facing toward the mold base <NUM> of the molding device <NUM>. In some embodiments, the first element <NUM> and the second element <NUM> can engage with each other, thereby tightly engaging the discharging channels <NUM> with the mold base <NUM> of the molding device <NUM>.

In some embodiments, in order to prevent separation of the extruding system <NUM> and the molding device <NUM> during the injection, the engaged first element <NUM> is subjected to a force to against the second element <NUM>. The force may be equal to or greater than a threshold. The threshold may be adjusted according to the pressure in the mold cavity <NUM> and the diameter of the outlet <NUM>, or according to other factors.

The position and number of the first element <NUM> may be adjusted according to requirements, and are not particularly limited. The position and number of the second element <NUM> may also be adjusted according to requirements, and are not particularly limited. In some embodiments, the position and number of the second element <NUM> correspond to the position and number of the first element <NUM>. In an embodiment, the first element <NUM> can be disposed at any suitable position on the discharging channel <NUM>, and the second element <NUM> can be disposed at any suitable position on the molding device <NUM>. In some embodiments, the second element <NUM> is disposed adjacent to the upper mold <NUM>.

<FIG> is a schematic diagram of a portion of the injection molding system <NUM> according to one embodiment of the present invention. In some embodiments, referring to <FIG>, the supporting device <NUM> can be in either of two states, a locked state and an unlocked state. In the unlocked state, the first element <NUM> enters the corresponding second element <NUM> but has not yet been locked with the second element <NUM>. In other words, the first element <NUM> can still be withdrawn from the second element <NUM> when the supporting device <NUM> is in the unlocked state. In the locked state, the first element <NUM> enters and locks with the corresponding second element <NUM>, such that the first element <NUM> cannot be withdrawn from the second element <NUM>. <FIG> illustrates the supporting device <NUM> in the locked state. The supporting device <NUM> can be operated and controlled manually or automatically. The supporting device <NUM> can be switched between two states manually or automatically.

In some embodiments, the first element <NUM> is rotatably fixed to the extruding system <NUM>. In some embodiments, the first element <NUM> includes an elongated portion <NUM> and an arm portion <NUM>. The elongated portion <NUM> and the arm portion <NUM> are rotatable in a direction indicated by an arrow A. The elongated portion <NUM> is fixed to the extruding system <NUM> and extends in a first direction Z toward the upper mold <NUM>. The arm portion <NUM> is coupled to the elongated portion <NUM> and extends in a second direction X substantially orthogonal to the first direction Z or in a third direction Y substantially orthogonal to the first direction Z. In some embodiments, the first element <NUM> has an inverted T shape. After the first element <NUM> enters the second element <NUM>, the supporting device <NUM> is changed from the unlocked state to the locked state by rotation of the arm portion <NUM> of the first element <NUM>. In some embodiments, the first element <NUM> is locked with the second element <NUM> by rotating the arm portion <NUM> of the first element <NUM> with about <NUM> degrees. <FIG> illustrates the arm portion <NUM> is locked with the second element <NUM> after rotating the arm portion <NUM> with about <NUM> degrees. As a result, the supporting device <NUM> is in the locked state, and the discharging channel <NUM> is tightly engaged with the molding device <NUM>, and thus the injection of the mixture from the extruding system <NUM> and the discharging channel <NUM> to the molding device <NUM> can begin.

In some embodiments, referring to <FIG>, the discharging channel <NUM> is secured to the molding device <NUM> by turning the supporting device <NUM> into the lock state, such as rotating a first element <NUM> of the supporting device <NUM> relative to and within a second element <NUM> of the supporting device <NUM> while engaging the outlet <NUM> with the feeding port <NUM>. In some embodiments, when the outlet <NUM> are docked to the feeding ports <NUM>, the first element <NUM> enters the second element <NUM> and then locked with the second element <NUM>. In some embodiments, the discharging channel <NUM> is secured to the molding device <NUM> by rotating an elongated portion <NUM> and an arm portion <NUM> of the first element <NUM> of the supporting device <NUM>, the elongated portion <NUM> is fixed to the extruding system <NUM> and extends in a first direction Z toward the molding device <NUM>, and the arm portion <NUM> is coupled to the elongated portion <NUM> and extends in a second direction X different from the first direction Z.

In some embodiments, referring to <FIG>, the method <NUM> further includes injecting a gas G into the mold cavity <NUM> through a pressure-regulating system <NUM> in connection with the mold cavity <NUM> until the mold cavity <NUM> is sensed to have a first predetermined pressure before injecting the molding material into the mold cavity <NUM>. In some embodiments, the gas G injected into the mold cavity <NUM> through a first gas conduit <NUM>. In some embodiments, the gas G is any suitable gas depending on the need; for example, air; however, the present invention is not limited thereto. In some embodiments, after the engagement of the outlets <NUM> and the feeding portion <NUM>, the pressure in the mold cavity <NUM> of the molding device <NUM> is adjusted to the first predetermined pressure. After the molding device <NUM> has the first predetermined pressure, the injection begins.

In some embodiments, the pressure sensing unit <NUM> senses that the pressure in the mold cavity <NUM> is the atmospheric pressure. In some embodiments, a first valve <NUM> is opened so that a gas G is injected into the mold cavity <NUM> through the first gas conduit <NUM>. In some embodiments, the gas G is injected into the mold cavity <NUM> through the pressure-regulating system <NUM> when the feeding port <NUM> is closed. In some embodiments, the gas G is injected into the mold cavity <NUM> through the feeding port <NUM>.

In some embodiments, during the process of injecting the gas G into the mold cavity <NUM>, the pressure in the mold cavity <NUM> is sensed continuously. In some embodiments, the pressure sensing unit <NUM> continuously senses the pressure in the mold cavity <NUM>, and the gas G is injected into the mold cavity <NUM> until it is senses that the mold cavity <NUM> has the first predetermined pressure; then, the first valve <NUM> and the second valve <NUM> of the pressure-regulating system <NUM> are closed, and the gas G injection into the mold cavity <NUM> is stopped. In some embodiments, the first predetermined pressure is greater than the atmospheric pressure. In some embodiments, the first predetermined pressure is less than the atmospheric pressure.

In some embodiments, the mold cavity <NUM> has the first predetermined pressure before operation <NUM>, and the first valve <NUM> and the second valve <NUM> of the pressure-regulating system <NUM> are closed.

According to the invention, the method <NUM> includes operation <NUM>, which includes injecting a first material M1 into the mold cavity <NUM>. In some embodiments, the molding material made by the extruding system <NUM> is the first material M1. The first material M1 includes a polymeric material and a blowing agent. In some embodiments, referring to <FIG>, the first material M1 is injected into the mold cavity <NUM> through the outlet <NUM> and the feeding port <NUM>. In some embodiments, operation <NUM> includes injecting the first material M1 from the discharging channel <NUM> into the mold cavity <NUM> through the outlet <NUM> and the feeding port <NUM>. In some embodiments, the discharging channel <NUM> is at least partially surrounded by the molding device <NUM> upon the injection of the first material M1.

In some embodiments, at least a portion the first material M1 is disposed between the inner wall <NUM> of the first mold <NUM> and the core <NUM>. In some embodiments, at least a portion the first material M1 is disposed between the supporting units <NUM>, <NUM>, <NUM>. In some embodiments, at least a portion of the first material M1 is disposed within the recess <NUM> or the through hole <NUM> of the core <NUM>. In some embodiments, at least a portion of the first material M1 surrounds the protrusion <NUM> of the core <NUM>.

In some embodiments, in operation <NUM>, during the process of injecting the first material M1 into the mold cavity <NUM> of the molding device <NUM>, the pressure in the mold cavity <NUM> changes rapidly, and the pressure-sensing unit <NUM> continuously senses the pressure in the mold cavity <NUM>. In some embodiments, the first material M1 is injected into the mold cavity <NUM> of the molding device <NUM> from the feeding port <NUM>, and the first predetermined pressure applies to the first material M1. In some embodiments, the first material M1 and the gas G are disposed in the mold cavity <NUM>, and the first material M1 will expand and foam in the mold cavity <NUM>.

In some embodiments, the first material M1 is injected into the mold cavity <NUM> of the molding device <NUM> from the feeding port <NUM>, and thereby increasing the pressure in the mold cavity <NUM>. In some embodiments, the pressure in the mold cavity <NUM> of the molding device <NUM> is raised above the first predetermined pressure. In some embodiments, the pressure in the mold cavity <NUM> of the molding device <NUM> is raised from the first predetermined pressure to a second predetermined pressure.

In some embodiments, after the first material M1 is injected into the mold cavity <NUM> having the first predetermined pressure, the pressure in the mold cavity <NUM> increases, and therefore, the setting of a second predetermined pressure ensures that the mold cavity <NUM> is maintained within a suitable pressure range. In some embodiments, when the mold cavity <NUM> reaches the second predetermined pressure, the injection of first material M1 into the mold cavity <NUM> is stopped.

In some embodiments, the process of injecting the first material M1 into the mold cavity <NUM> having the first predetermined pressure lasts for less than <NUM> second. In some embodiments, due to the mold cavity <NUM> has the first predetermined pressure, the completion of the filling the first material M1 may be last for less than <NUM> second. During the injecting period or at the moment of the completion of the injection, the pressure in the mold cavity <NUM> is sensed by the pressure-sensing unit <NUM> in real time, and the pressure information is provided, so that the pressure-regulating system <NUM> can adjust the pressure in the mold cavity <NUM> in accordance with the pressure information, and hence, the pressure in the mold cavity <NUM> can be kept within the predetermined pressure range.

In some embodiments, during the process of injection, the temperature of the discharging channel <NUM> is greater than that of the molding device <NUM>. In some embodiments, the temperature difference is maintained using the insulator <NUM>.

According to the invention, referring to <FIG>, in operation <NUM>, the method <NUM> includes foaming the first material M1 to form a first foamed member <NUM>. At least a portion of the first foamed member <NUM> is in contact with the core <NUM>. In some embodiments, at least a portion of the foamed member <NUM> is in contact with at least a portion of the first surface <NUM>, the entire sidewall <NUM> and the entire second surface <NUM> of the core <NUM>. In some embodiments, the first surface <NUM> includes a first portion and a second portion, the first portion is in contact with the first foamed member <NUM>, and the second portion is in contact with the supporting member <NUM>.

In some embodiments, at least a portion the first foamed member <NUM> is disposed between the inner wall <NUM> of the first mold <NUM> and the core <NUM>. In some embodiments, at least a portion the first material M1 is disposed between the supporting units <NUM>, <NUM>, <NUM>. In some embodiments, at least a portion of the first foamed member <NUM> is disposed within the recess <NUM> or the through hole <NUM> of the core <NUM>. In some embodiments, at least a portion of the first foamed member <NUM> surrounds the protrusion <NUM> of the core <NUM>. In some embodiments, an article <NUM>-<NUM> is formed after the first foamed member <NUM> is formed. In some embodiments, the article <NUM>-<NUM> includes the core <NUM> and the first foamed member <NUM>.

According to the invention, the method <NUM> further includes retracting the supporting member <NUM> into the first mold <NUM> or removing the supporting member <NUM> from the mold cavity <NUM> during or after the injecting the first material M1. In some embodiments, at least one of the supporting units <NUM>, <NUM>, <NUM> is retreated or removed after the first foamed member <NUM> is foamed. In some embodiments, after the supporting member <NUM> is retreated or removed, a mark <NUM> is formed on the first foamed member <NUM>. In some embodiments, the mark <NUM> is formed at a position corresponding the position of the supporting member <NUM>. In some embodiments, after the supporting units <NUM>, <NUM>, <NUM> are retreated or removed, the marks <NUM>, <NUM>, <NUM> are formed at the positions corresponding to the positions of the supporting units <NUM>, <NUM>, <NUM>, respectively. In some embodiments, the article <NUM>-<NUM> includes the marks <NUM>, <NUM>, <NUM>. In some embodiments, the article <NUM>-<NUM> is free from the marks <NUM>, <NUM>, <NUM>. The first foamed member <NUM> of article <NUM>-<NUM> encloses the core <NUM>. In some embodiments, the article <NUM>-<NUM> may be further pick out from the molding device <NUM>.

In some embodiments, the second portion of the first surface <NUM> of the core <NUM> is exposed through the mark <NUM>, and the feeding opening <NUM> is disposed adjacent to the mark <NUM>. In some embodiments, each of the feeding openings <NUM> is disposed adjacent to the corresponding one of the marks <NUM>, <NUM>, <NUM>.

In some embodiments, the method <NUM> further includes discharging the gas G from the mold cavity <NUM> to decrease a pressure in the mold cavity <NUM> to a third predetermined pressure. In some embodiments, a portion of the gas G is discharged from the mold cavity <NUM> after injecting the gas G into the mold cavity <NUM>. In some embodiments, during operation <NUM>, the gas G is discharged in less than <NUM> second from the mold cavity <NUM> through the pressure-regulating system <NUM> while the first material M1 is foaming in the mold cavity <NUM>. Due to the discharging of the gas G, the first material M1 in the mold cavity <NUM> after the foaming process may have a lower density. In some embodiments, the gas G is discharged from the mold cavity <NUM> through the junction point <NUM>. In some embodiments, the gas G is discharged from the mold cavity <NUM> during or after the foaming process of the first material M1 in the mold cavity <NUM>. In some embodiments, the pressure in the mold cavity <NUM> is decreased from the second predetermined pressure.

In some embodiments, when the pressure-sensing unit <NUM> senses that the pressure in the mold cavity <NUM> is greater than the second predetermined pressure, a portion of the gas G in the mold cavity <NUM> is discharged until the pressure in the mold cavity <NUM> is within a predetermined pressure range. In some embodiments, the predetermined pressure range is between the first predetermined pressure and the second predetermined pressure. In some embodiments, the second valve <NUM> is open and a portion of the gas G in the mold cavity <NUM> is discharged through the second gas conduit <NUM>.

According to the invention, referring to <FIG>, the method <NUM> further includes injecting a second material M2 into the mold cavity <NUM> after the supporting member <NUM> is removed or retracted. In some embodiments, a ratio of a polymeric material to a blowing agent in the first material M1 is substantially equal to a ratio of the polymeric material to the blowing agent in the second material M2. In some embodiments, composition of the first material M1 is similar to that of the second material M2. In some embodiments, the core <NUM> is enclosed by the first material M1 and the second material M2.

In some embodiments, the molding material made by the extruding system <NUM> is the second material M2. In some embodiments, the second material M2 is injected into the mold cavity <NUM> through the outlet <NUM> and the feeding port <NUM>. In some embodiments, the second material M2 is injected from the discharging channel <NUM> into the mold cavity <NUM> through the outlet <NUM> and the feeding port <NUM>. In some embodiments, the discharging channel <NUM> is at least partially surrounded by the molding device <NUM> upon the injection of the second material M2.

In some embodiments, a position where the second material M2 disposed is corresponding to the position of the supporting member <NUM>. In some embodiments, the second material M2 is disposed within the mark <NUM>. In some embodiments, after the marks <NUM>, <NUM>, <NUM> are formed at the positions corresponding to the positions of the supporting units <NUM>, <NUM>, <NUM>, respectively, the second material M2 is disposed within the marks <NUM>, <NUM>, <NUM>. In some embodiments, at least a portion of the second material M2 is in contact the first surface <NUM> of the core <NUM>. In some embodiments, the first foamed member <NUM> surrounds the second material M2. In some embodiments, at least a portion of the second material M2 is in contact the first foamed member <NUM>.

According to the invention, the method <NUM> further includes foaming the second material M2 to form a second foamed member <NUM>. According to the invention, the core <NUM> is enclosed by the first foamed member <NUM> and the second foamed member <NUM>. In some embodiments, at least a portion of the second foamed member <NUM> is in contact the first surface <NUM> of the core <NUM>. According to the invention, the first foamed member <NUM> surrounds the second foamed member <NUM>. In some embodiments, at least a portion of the second foamed member <NUM> is in contact the first foamed member <NUM>. In some embodiments, an article <NUM>-<NUM> is formed after the first foamed member <NUM> and the second foamed member <NUM> are formed. According to the invention, the article includes the core <NUM>, the first foamed member <NUM> and the second foamed member <NUM>.

In some embodiments, after the formation of the second foamed member <NUM>, the second mold <NUM> leaves the first mold <NUM>, and the discharging channel <NUM> is disengaged and withdrawn from the molding device <NUM>, as shown in <FIG>. The outlet <NUM> is disengaged with the feeding port <NUM>. The molding device <NUM> is changed from the closed configuration (<FIG>) to an open configuration (<FIG>).

In some embodiments, referring to <FIG>, after the formation of the article <NUM>-<NUM>, the article <NUM>-<NUM> is then picked out from the first mold <NUM>. In some embodiments, the article <NUM>-<NUM> is picked out manually by human, or automatically by robot, robotic arm, gripper or the like.

In some embodiments, the method <NUM> further includes disposing a component <NUM> within an opening <NUM> of the second mold <NUM> prior to the injection of the first material M1. <FIG> are schematic cross-sectional views illustrating an injection molding system <NUM> of the operations <NUM> to <NUM> of the method <NUM> in accordance with some embodiments of the present disclosure. <FIG> and <FIG> are schematic cross-sectional views illustrating an article <NUM>-<NUM> manufactured by the method <NUM> in accordance with some embodiments of the present disclosure.

In some embodiments, referring to <FIG>, the second mold <NUM> is in another configuration that includes an opening <NUM>. In some embodiments, the second mold <NUM> includes an opening <NUM> disposed opposite to the first mold <NUM>. In some embodiments, referring to <FIG>, a component <NUM> is receivable by and disposed within the opening <NUM>. In some embodiments, the mold cavity <NUM> is defined by the first mold <NUM>, the second mold <NUM> and the component <NUM> as shown in <FIG>. In some embodiments, the first material M1 is injected into the mold cavity <NUM> between the component <NUM> and the inner wall <NUM> of the first mold <NUM> as shown in <FIG>, similar to the operation as shown in <FIG>. The component <NUM> is in contact with the first material M1 during formation of the first foamed member <NUM>. As such, an article <NUM>-<NUM> is fabricated shown in <FIG>. In some embodiments, the article <NUM>-<NUM> is a product or a semi-product including includes the component <NUM> and the first foamed member <NUM>, at least a portion of the first foamed member <NUM> is disposed between the core <NUM> and the component <NUM>. In some embodiments, the component <NUM> is an insole, a footwear upper or any other suitable component of the footwear.

According to the invention, referring to <FIG>, the article <NUM>-<NUM> further includes the mark <NUM>. In some embodiments, the article <NUM>-<NUM> further includes the plurality of marks <NUM>, <NUM>, <NUM>. According to the invention, referring to <FIG>, the article <NUM>-<NUM> further includes the second foamed member <NUM> formed by the second material M2.

In some embodiments, the method <NUM> includes injecting the first material M1 and the second material M2 from the extruding system <NUM> into the discharging channel <NUM>. <FIG> is a schematic diagram of the extruding system according to aspects of the present disclosure in some embodiments. The extruding system <NUM> includes a melting unit <NUM> and a mixing unit <NUM>. In some embodiments, the extruding system <NUM> includes the melting unit <NUM>, the mixing unit <NUM>, a blowing agent supply unit <NUM>, an injection unit <NUM>, a first flow control element <NUM>, a second flow control element <NUM>, and a monitoring module <NUM>.

In some embodiments, referring to <FIG>, the melting unit <NUM> is configured to convey the polymeric material. In some embodiments, the melting unit <NUM> includes a pressing cartridge <NUM>, a first feeding passage <NUM>, a first discharging passage <NUM>, and a pushing member <NUM>. In some embodiments, the melting unit <NUM> further includes a feeding hopper <NUM>.

In some embodiments, the first feeding passage <NUM> and the first discharging passage <NUM> are respectively disposed at two ends of the pressing cartridge <NUM>. In some embodiments, the first feeding passage <NUM> communicates with an inner space <NUM> of the pressing cartridge <NUM>, and the first discharging passage <NUM> communicates with an external space of the pressing cartridge <NUM>, wherein the first feeding passage <NUM> is configured to deliver the polymeric material to the inner space <NUM> of the pressing cartridge <NUM>. In some embodiments, the feeding hopper <NUM> is configured to deliver a polymeric material to the inner space <NUM> of the pressing cartridge <NUM> through the first feeding passage <NUM>.

The pushing member <NUM> is configured to convey the polymeric material from the first feeding passage <NUM> to the first discharging passage <NUM>. In some embodiments, the pushing member <NUM> is disposed in the inner space <NUM> of the pressing cartridge <NUM>. In some embodiments, the pushing member <NUM> is disposed in the inner space <NUM> of the pressing cartridge <NUM> between the first feeding passage <NUM> and the first discharging passage <NUM>, and is used to force the polymeric material toward the first discharging passage <NUM>. In some embodiments, the pushing member <NUM> is rotatable relative to the pressing cartridge <NUM>. In some embodiments, the polymeric material is conveyed from the first feeding passage <NUM> to the first discharging passage <NUM> by rotation of the pushing member <NUM>. In some embodiments, the pushing member <NUM> is immovable in a direction parallel to the longitudinal axis of the pressing cartridge <NUM>.

In some embodiments, a length of the pushing member <NUM> extends along a length of the pressing cartridge <NUM>, and a ratio of a shortest distance D5 between an inner sidewall <NUM> of the pressing cartridge <NUM> and the pushing member <NUM> and a diameter D6 of the pushing member <NUM> is in a range of about <NUM>:<NUM> to about <NUM>:<NUM>, and the polymeric material melted by the melting unit <NUM> may be uniformed. In some embodiments, the shortest distance D5 between an inner sidewall <NUM> of the pressing cartridge <NUM> and the pushing member <NUM> is substantially equal to or less than <NUM>. In some embodiments, the shortest distance D5 between the inner sidewall <NUM> of the pressing cartridge <NUM> and the pushing member <NUM> ranges between <NUM> and <NUM>.

The mixing unit <NUM> is configured to receive the polymeric material from the melting unit <NUM> and configured to mix the polymeric material with a blowing agent and to form a mixture of the polymeric material and the blowing agent. The mixing unit <NUM> includes a hollow mixing cartridge <NUM>, a second feeding passage <NUM>, a second discharging passage <NUM>, and a mixing rotor <NUM>.

The second feeding passage <NUM> and the second discharging passage <NUM> are respectively disposed at two ends of the mixing cartridge <NUM>. In some embodiments, the second feeding passage <NUM> is configured to deliver the polymeric material. In some embodiments, the second discharging passage <NUM> is configured to discharge the mixture.

The mixing rotor <NUM> is configured to mix the polymeric material with the blowing agent to form a mixture in the mixing cartridge <NUM>. In some embodiments, the mixing rotor <NUM> is disposed in the mixing cartridge <NUM>. In some embodiments, the mixing rotor <NUM> is disposed in the mixing cartridge <NUM> between the second feeding passage <NUM> and the second discharging passage <NUM>, so as to agitate the mixture in the mixing cartridge. The mixing rotor <NUM> is rotatable to mix the polymeric material with the blowing agent and to convey the mixture of the polymeric material and the blowing agent from the second feeding passage <NUM> to the second discharging passage <NUM>. In some embodiments, the mixing rotor <NUM> is immovable in a direction parallel to the longitudinal axis of the mixing cartridge <NUM>.

In some embodiments, a length of the mixing rotor <NUM> extends along a length of the hollow mixing cartridge <NUM>, and a ratio of a shortest distance D3 between an inner sidewall <NUM> of the hollow mixing cartridge <NUM> and the mixing rotor <NUM> and a diameter D4 of the mixing rotor <NUM> is in a range of about <NUM>:<NUM> to about <NUM>:<NUM>, and the mixture prepared by the extruding system <NUM> may be even and uniformed. In some embodiments, the mixture may be divided in to a plurality of portions, and a ratio of the blowing agent to the polymeric material of each portion of the mixture prepared by the extruding system <NUM> is substantially constant. In some embodiments, a ratio of the polymeric material to the blowing agent in a first portion of the mixture is substantially equal to a ratio of the polymeric material to the blowing agent in a second portion of the mixture. In some embodiments, the shortest distance D3 between the inner sidewall <NUM> of the hollow mixing cartridge <NUM> and the mixing rotor <NUM> is substantially equal to or less than <NUM>. In some embodiments, the shortest distance D3 between the inner sidewall <NUM> of the hollow mixing cartridge <NUM> and the mixing rotor <NUM> ranges between <NUM> and <NUM>.

<FIG> is an enlarged view of a portion of the extruding system according to aspects of the present disclosure in some embodiments. To enable the melted polymeric material and the blowing agent to mix uniformly in the mixing cartridge <NUM>, in some embodiments, referring to <FIG> and <FIG>, the mixing rotor <NUM> further includes a column-like body <NUM> in a cylindrical shape and rotatably disposed in the mixing cartridge <NUM>, and a groove portion <NUM> annularly arranged on the periphery of the column-like body <NUM>. Therefore, when the column-like body <NUM> rotates, the polymeric material and the blowing agent are agitated by the groove portion <NUM>, so as to achieve a desired mixing effect. In some embodiments, the shortest distance D3 is a shortest distance between the groove portion <NUM> and the inner sidewall <NUM> of the hollow mixing cartridge <NUM>.

In some embodiments, when the shortest distance D3 is a shortest distance between the groove portion <NUM> and the inner sidewall <NUM> of the hollow mixing cartridge <NUM>, the shortest distance D3 ranges between <NUM> and <NUM>. In some embodiments, the diameter D4 of the mixing rotor <NUM> ranges between the <NUM> to <NUM>. Table <NUM> lists the shortest distance D3, the diameter D4 and the corresponding ratio of the a shortest distance D3 distance between the groove portion <NUM> and the inner sidewall <NUM> of the hollow mixing cartridge <NUM> and a diameter D4 of the mixing rotor <NUM>.

In some embodiments, when the shortest distance D3 is substantially less than <NUM>, the blowing agent in a predetermined amount of the mixture is substantially greater than <NUM> per cm<NUM>, as shown in <FIG>. In some embodiments, if the blowing agent in the predetermined amount of the mixture is substantially greater than <NUM> per cm<NUM>, a bubble density in the predetermined amount of the mixture after foaming is substantially greater than <NUM> per cm<NUM>.

In some embodiments, when the ratio of the shortest distance D3 to the distance D4 ranges between <NUM>:<NUM> and <NUM>:<NUM>, an evenness of the blowing agent to the polymeric material is optimized. In other words, a mixing of the blowing agent and the polymeric material by the mixing rotor <NUM> is even and uniform. In some embodiments, when the ratio of the shortest distance D3 to the distance D4 ranges between <NUM>:<NUM> and <NUM>:<NUM>, a ratio of the blowing agent to the polymeric material in a predetermined amount of the mixture ranges between <NUM>:<NUM> to <NUM>:<NUM> as shown in <FIG>. In some embodiments, the ratio of the blowing agent to the polymeric material in the predetermined amount of the mixture is about <NUM>:<NUM>. In some embodiments, if the ratio of the blowing agent to the polymeric material in the predetermined amount of the mixture ranges between <NUM>:<NUM> and <NUM>:<NUM> ratio of bubbles to the polymeric material in the predetermined amount of the mixture after foaming also ranges between <NUM>:<NUM> and <NUM>:<NUM>. In some embodiments, the ratio of the bubbles to the polymeric material in the predetermined amount of the mixture after foaming is about <NUM>:<NUM>.

In some embodiments, referring back to <FIG>, the melting unit <NUM> includes a hollow pressing cartridge <NUM> configured to accommodate the polymeric material and having a first pressure, and the mixing unit <NUM> includes a hollow mixing cartridge <NUM> having a second pressure. In some embodiments, in order to prevent backflow, the first pressure is greater than the second pressure. In some embodiments, the polymeric material is drawn from the melting unit <NUM> toward the mixing unit <NUM> by the difference between the first pressure and the second pressure.

The blowing agent supply unit <NUM> is connected to the mixing unit <NUM> and configured to convey the blowing agent into the mixing unit <NUM>. In some embodiments, the blowing agent supply unit <NUM> is positioned between the first flow control element <NUM> and the second flow control element <NUM>. In some embodiments, the blowing agent supply unit <NUM> is disposed proximal to the first flow control element <NUM> and distal to the second flow control element <NUM>.

In some embodiments, a blowing agent source (not shown) is connected to the blowing agent supply unit <NUM> and is configured to supply any type of blowing agent known to those of ordinary skill in the art. In some embodiments, the blowing agent is in the supercritical fluid state after being introduced into the mixing unit <NUM> by the blowing agent supply unit <NUM>.

In some embodiments, the first flow control element <NUM> is disposed at a first port <NUM> that connects the melting unit <NUM> to the mixing unit <NUM>. The first port <NUM> is configured to introduce the polymeric material from the melting unit <NUM> into the mixing unit <NUM>. The first port <NUM> is located between the melting unit <NUM> and the mixing unit <NUM>. In some embodiments, the first port <NUM> is configured to introduce the polymeric material from the pressing cartridge <NUM> of the melting unit <NUM> into the mixing cartridge <NUM> of the mixing unit <NUM>. In some embodiments, the polymeric material can be conveyed and/or drawn from the melting unit <NUM> to the mixing unit <NUM> through the first port <NUM> by a pressure difference between the first pressure and the second pressure.

In some embodiments, the first flow control element <NUM> is disposed between the melting unit <NUM> and the mixing unit <NUM> and is configured to control flow of the polymeric material from the melting unit <NUM> to the mixing unit <NUM>. The first flow control element <NUM> may be a valve, a movable cover or the like.

In some embodiments, the first flow control element <NUM> is configured to switch between an open configuration and a closed configuration. The open configuration of the first flow control element <NUM> allows the polymeric material to flow from the melting unit <NUM> into the mixing unit <NUM>, and the closed configuration of the first flow control element <NUM> prevents the polymeric material from flowing from the mixing unit <NUM> back to the melting unit <NUM>.

In some embodiments, the first flow control element <NUM> is configured to maintain a pressure difference between the melting unit <NUM> and the mixing unit <NUM>. In some embodiments, the first flow control element <NUM> is configured to maintain a pressure difference between the melting unit <NUM> and the mixing unit <NUM> by switching between the open configuration and the closed configuration, so that the polymeric material is not able to flow from the mixing cartridge <NUM> of the mixing unit <NUM> back to the pressing cartridge <NUM> of the melting unit <NUM>. In some embodiments, the first flow control element <NUM> is configured to adjust the first pressure and/or the second pressure in order to maintain the pressure difference between the first pressure and the second pressure. In some embodiments, the first flow control element <NUM> is in the closed configuration when the first pressure is similar to the second pressure.

In some embodiments, the injection unit <NUM> is configured to receive the mixture discharged from the second discharging passage <NUM> of the mixing unit <NUM> and to discharge the mixture out of the injection unit <NUM>. In some embodiments, the injection unit <NUM> is configured to inject the mixture, and the discharging channel <NUM> is communicable with the injection unit <NUM>.

In some embodiments, the injection unit <NUM> includes a hollow metering cartridge <NUM> configured to accommodate the mixture. The metering cartridge <NUM> has a hollow inner space <NUM>, wherein the inner space <NUM> is in communication with the second discharging passage <NUM> and configured to accommodate the mixture. The injection unit <NUM> further includes a connecting passage <NUM> in communication with the inner space <NUM> of the metering cartridge <NUM> and a discharging member <NUM> slidably disposed in the inner space <NUM> of the metering cartridge <NUM> and configured to discharge the mixture out of the metering cartridge <NUM> through an outlet <NUM>.

In some embodiments, the mixture is flowed from the injection unit <NUM> into the discharging channel <NUM>. In some embodiments, the mixture is the first material M1 and/or the second material M2.

An aspect of this disclosure relates to an article. The article includes a foamed member including a polymeric material; and a core embedded in the foamed member; wherein the core includes a first surface, a second surface opposite to the first surface, and a sidewall between the first surface and the second surface, the foamed member covers at least a portion of the first surface, and covers the entire sidewall and the entire second surface.

In some embodiments, the core includes a through hole extending between the first surface and the second surface. In some embodiments, a recess indented into the core and disposed at the first surface, the second surface or the sidewall. In some embodiments, the core includes a protrusion protruded from the first surface, the second surface or the sidewall, and the protrusion is surrounded by the foamed member. In some embodiments, the article further comprising a component disposed over the core and the foamed member, and a portion of the foamed member is disposed between the component and the core. In some embodiments, the core is enclosed by the foamed member.

An aspect of this disclosure relates to a method of manufacturing an article. The method includes providing a molding device, wherein the molding device includes a first mold, a second mold corresponding to the first mold, the first mold includes an inner wall and a supporting member protruded from the inner wall; disposing a core on the supporting member; disposing the second mold over the first mold to form a mold cavity defined by the first mold and the second mold, wherein the core is disposed within the mold cavity; injecting a first material into the mold cavity; and foaming the first material to form a first foamed member; wherein at least a portion of the first foamed member is in contact with the core.

In some embodiments, the method further includes retracting the supporting member into the first mold or removing the supporting member from the mold cavity during or after the injecting the first material. In some embodiments, the method further includes injecting a second material into the mold cavity after the supporting member is removed or retracted. In some embodiments, a ratio of a polymeric material to a blowing agent in the first material is substantially equal to a ratio of the polymeric material to the blowing agent in the second material. In some embodiments, the method further includes forming a mark on the first foamed member at a position corresponding to the supporting member. In some embodiments, the method further includes injecting a gas into the mold cavity to increase a pressure in the mold cavity to a first predetermined pressure before the injecting the first material. In some embodiments, the method further includes discharging a gas from the mold cavity to decrease a pressure in the mold cavity to a second predetermined pressure. In some embodiments, at least a portion of the first material is disposed within a recess or a through hole of the core.

In some embodiments, at least a portion the first material is disposed between the inner wall and the core. In some embodiments, the supporting member includes a plurality of supporting units protruded from the inner wall, and at least a portion the first material is disposed between the supporting units. In some embodiments, the core includes a first surface contacting the supporting member, a second surface opposite to the first surface, and a sidewall between the first surface and the second surface, the first foamed member is in contact with at least a portion of the first surface, and covers the entire sidewall and the entire second surface. In some embodiments, the method further incudes disposing a component within an opening of the second mold prior to the injection of the first material. In some embodiments, at least a portion of the first material is disposed between the component and the core after the injecting the first material. In some embodiments, the method further includes providing an extruding system configured to produce the first material and having a melting unit and a mixing unit; and providing a discharging channel communicable with the extruding system and including an outlet disposed distal to the extruding system and configured to discharge the molding material, wherein a feeding port of the molding device is correspondingly engageable with the outlet.

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.

Claim 1:
An article (<NUM>), comprising:
a core (<NUM>) embedded in the foamed member (<NUM>), wherein the core (<NUM>) includes a first surface (<NUM>), a second surface (<NUM>) opposite to the first surface (<NUM>), and a sidewall (<NUM>) between the first surface (<NUM>) and the second surface (<NUM>);
a first foamed member (<NUM>) covered the entire sidewall (<NUM>) and the entire second surface (<NUM>) and a first portion of the first surface (<NUM>);
a mark (<NUM>) formed on the first foamed member (<NUM>), and a second portion of the first surface (<NUM>) of the core (<NUM>) is exposed through the mark (<NUM>); characterized in that
a second foamed member (<NUM>) disposed within the mark (<NUM>) and surrounded by the first foamed member (<NUM>), a first portion of the second foamed member (<NUM>) is in contact with the second portion of the first surface (<NUM>) of the core (<NUM>),
wherein a second portion of the second foamed member (<NUM>) is in contact the first foamed member (<NUM>), and the core (<NUM>) is enclosed by the first foamed member (<NUM>) and the second foamed member (<NUM>).