Patent ID: 12186954

DETAILED DESCRIPTION

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. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

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 10%, 5%, 1%, or 0.5% 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.1is a schematic cross-sectional view illustrating an injection molding system100. In some embodiments, the injection molding system100includes a molding device101, a plunger104and an injection station105. In some embodiments, the injection station105is configured to receive the molding device101. The platform105ais configured to dispose the molding device101. The injector105bis configured to discharge a fluid or liquid from an outlet105c. In some embodiments, a first opening105dextending through the platform105ais included. In some embodiments, the injector105bis disposed above the first opening105d. In some embodiments, the injector105bis overlapped with the first opening105dfrom a top view. In some embodiments, the injection station105further includes a chamber105e. The platform105aand the injector105bare disposed above the chamber105e. The molding device101is disposed in the injection station105.

In some embodiments, the molding device101is provided or received as shown inFIG.1. In some embodiments, the molding device101includes a mold cavity101eand a clamping unit102for clamping the molding device101. In some embodiments, the molding device101is configured for forming an article in the mold cavity101e, such as a formed article. In some embodiments, the fluid or liquid is injected into the mold cavity101eand then the article is formed in the mold cavity101eafter a period of time.

In some embodiments, the mold cavity101eis defined by a first mold base101dand a second mold base101cdisposed over and corresponding to the first mold base101d. In some embodiments, the molding device101further includes a first mold101bdisposed in the first mold base101dand a second mold101adisposed over and corresponding to the first mold101b. In some embodiments, the second mold101acorresponds to the first mold101bin some configurations such as dimension, shape or the like. The second mold101acan be placed on and engaged with the first mold101b. In some embodiments, the mold cavity101eis defined by the second mold101aand the first mold101b. In some embodiments, the second mold base101ccorresponds to the first mold base101din some configurations such as dimension, shape or the like. The second mold base101ccan be placed above the first mold base101d.

In some embodiments, the molding device101further includes a first passage101fextending through the second mold101aand the second mold base101c. The first passage101fis configured to allow the fluid or liquid flowing through. In some embodiments, the first passage101fis communicable with the mold cavity101e.

In some embodiments, the first mold base101dfurther includes a second opening101gconfigured to receive at least a portion of the plunger104. In some embodiments, the second opening101gis overlapped with the first opening105dfrom a top view. In some embodiments, the fluid or liquid is forced and pushed into the mold cavity101ethrough the outlet105cby an injecting force. In some embodiments, a direction of the injecting force is from the injector105btowards the second opening101g.

In some embodiments, the clamping unit102is disposed between the first mold base101dand the second mold base101c. In some embodiments, the second mold base101cis coupled with the first mold base101dby the clamping unit102. In some embodiments, the clamping unit102is adjacent to the first mold101band the second mold101a. In some embodiments, the molding device101includes a plurality of clamping units102. In some embodiments, the clamping unit102is configured to apply a clamping force to the second mold101aand the first mold101b. The clamping force can be applied on the second mold base101ctowards the first mold base101dor vice versa.

In some embodiments, the second mold101aand the first mold101bcan maintain engagement with each other by the clamping force provided by the clamping unit102. In other words, the molding device101can maintain in a closed configuration as shown inFIG.1by the clamping force from the clamping unit102. 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 5 Newton (N) to 15N. In some embodiments, the clamping force is about 10N.

In some embodiments, a gas is initially injected into the mold cavity101e, and the clamping force is applied to the molding device101by the clamping unit102in order to maintain the mold cavity101eat a predetermined pressure. In some embodiments, the molding device101is maintained in the closed configuration by the clamping force from the clamping unit102throughout the injection molding process.

In some embodiments, the fluid or liquid discharged from the outlet105cincludes a polymeric material. In some embodiments, the polymeric material is flowable along the injector105band dischargeable from the outlet105c. 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.

In some embodiments, the molding device101further includes a locking device103. In some embodiments, the locking device103is configured to lock the molding device101on the platform105a. In some embodiments, the locking device103is configured to facilitate a temporarily engagement of the molding device101to the injection station105. In some embodiments, the locking device103is used to prevent movement of the molding devices101during the injection of the fluid or the liquid into the mold cavity101e. The locking device103can be disposed at any suitable position.

In some embodiments, the locking device103includes a first locking element103adisposed on the molding device101and a second locking element103bdisposed on the platform105aand corresponding to the first locking element103a. In some embodiments, the first locking element103ais disposed on the first mold base101d. In some embodiments, the first and second locking elements103a,103bcan be clamped to or engage with each other, but the disclosure is not limited thereto. In some embodiments, the first locking element103ais overlapped with the second locking element103bwhen the first and second locking elements103a,103bare clamped to or engage with each other.

In some embodiments, the first locking element103ais a part of the molding device101, while the second locking element103bis a part of the platform105a. In some embodiments, the first locking element103aand the second locking element103bare configured complementary with each other. In some embodiments, the first locking element103aprotrudes from the molding device101, and the second locking element103bis configured to receive the first locking element103a. In some embodiments, the second locking element103bprotrudes from the platform105a, and the first locking element103ais configured to receive the second locking element103b. The position and number of the first locking element103amay be adjusted according to requirements, and are not particularly limited. The position and number of the second locking element103bmay also be adjusted according to requirements, and are not particularly limited. In some embodiments, the position and number of the second locking element103bcorrespond to the position and number of the first locking element103a.

In some embodiments, the plunger104includes a base104aand a rod104b. The plunger104is configured to provide a plunging force. In some embodiments, the plunger104is a hydraulic plunger. In some embodiments, the rod104bis extendable and retractable. In some embodiments, the rod104bis 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 plunger104is movable relative to the injection station105. In some embodiments, the plunger104is separated from the injection station105, and may be moved into the injection station105. In some embodiments, the plunger104is not movable and is initially fixed in the injection station105. In some embodiments, the plunger104is fixedly disposed under the platform105a, and the rod104bis vertically aligned with the first opening105d. In some embodiments, the plunger104is initially fixed in the chamber105e.

FIG.2is a flowchart showing a method M10of injection molding method in accordance with some embodiments of the present disclosure. The method M10includes 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; (O102) 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; (O103) 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; (O104) moving the injector towards the molding device to communicate with the mold cavity; (O105) applying a plunging force on the molding device by extending the rod through the first opening towards the molding device; and (O106) injecting a molding material from the injector into the mold cavity.

In order to illustrate concepts and the method M10of 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 M10is implemented by the injection molding system100as shown inFIG.1, andFIGS.3-8are schematic cross-sectional views of various stages of the injection molding method.

In some embodiments, the method M10of injection molding method includes operation O101, which includes providing the injection station105as shown inFIG.3. The injection station105includes a platform105aand an injector105bdisposed over the platform105a. In some embodiments, the platform105aincludes a first opening105dextending through the platform105a.

In some embodiments, the method M10of injection molding method includes operation O102, which includes conveying the molding device101to the injection station105and disposing the molding device101between the injector105band the platform105aas shown inFIG.3. In some embodiments, the molding device101is disposed in the injection station105. In some embodiments, the molding device101at least includes the first mold101b, the second mold101aover the first mold101band the mold cavity101edefined by the first mold101band the second mold101a.

The molding device101is moved towards the injection station105and placed on the platform105aas shown inFIG.3. During the movement of the molding device101, the molding device101is maintained in the closed configuration by the clamping unit102. In some embodiments, the mold cavity101eis maintained at the predetermined pressure during the movement of the molding device101. In some embodiments, the second mold101aand the first mold101bcan maintain engagement with each other by the clamping force provided by the clamping unit102. 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 5 Newton (N) to 15N. In some embodiments, the clamping force is about 10N.

In some embodiments, the molding device101is engaged with the platform105a. In some embodiments, the first locking element103ais vertically aligned with the second locking element103b. In some embodiments, the second opening101gis overlapped with the first opening105dfrom a top view.

In some embodiments, the outlet105cof the injector105bis disposed above the first passage101fof the molding device101. In some embodiments, a second passage104cincluding the first opening105dand the second opening101gis formed after placing the molding device101on the platform105a. In some embodiments, the second passage104cextends through the platform105aand the first mold base101d. In some embodiments, the first passage101fis overlapped with the second passage104cfrom a top view. In some embodiments, the injector105bmay be extended into and be retracted from the molding device101. In some embodiments, the injector105band the outlet105care overlapped with the first passage101ffrom a top view.

In some embodiments, the method M10of injection molding method includes operation O103, which includes disposing the plunger104under the molding device101and the platform105a. In some embodiments, the plunger104includes a base104aand a rod104bextendable toward the molding device101and retractable toward the base104a. In some embodiments, the method M10further includes aligning the injector105bwith the rod104bbefore and during injecting the fluid or the liquid.

The plunger104is moved towards the injection station105and placed under the platform105aas shown inFIG.3. In some embodiments, the plunger104is disposed in the injection station105and under the molding device101. In some embodiments, the plunger104is in the retracted configuration during the movement. In some embodiments, the plunger104is fixedly disposed under the molding device101and the first opening105d. In some embodiments, the rod104bof the plunger104is aligned with the second passage104cafter movement. In some embodiments, the plunger104is in a retracted configuration as shown inFIG.3. In some embodiments, the plunger104is disposed in the injection station105and under the molding device101. In some embodiments, the plunger104is disposed under the platform105a. In some embodiments, the plunger104is disposed in the chamber105e. In some embodiments, the rod104bis vertically aligned with the first opening105d. In some embodiments, the rod104bis extendable through the first opening105d. In some embodiments, the rod104bis extended and at least a portion of the rod104bis disposed in the second opening101g. In some embodiments, the rod104bis vertically aligned with the injector105band the outlet105c.

In some embodiments, the molding device101and the plunger104are conveyed into the injection station105simultaneously. In some embodiments, the molding device101and the plunger104are configured as a molding module106. In some embodiments, the molding device101and the plunger104are moved together into the injection station105. In some embodiments, the molding device101is disposed above and aligned with the plunger104before moving into the injection station105as shown inFIG.1. The second opening101gof the first mold base101dis vertically aligned with the rod104bof the plunger104.

FIG.4is a schematic cross-sectional view illustrating the operations O104and O105of the method M10in accordance with some embodiments of the present disclosure. In some embodiments, the method M10of injection molding method includes operation O104, which includes moving the injector105btowards the molding device101to communicate with the mold cavity101e.

In some embodiments, the injector105bis moved towards the molding device101after the engagement of the molding device101with the platform105a. In some embodiments, the injector105bis moved towards the molding device101after the engagement of the first locking element103aand the second locking element103b. In some embodiments, the outlet105cof the injector105bis engaged with the first passage101f, such that the fluid or liquid can flow from the injector105binto the mold cavity101ethrough the first passage101f.

In some embodiments, the method M10of injection molding method includes operation O105, which includes applying a plunging force on the molding device101by extending the rod104bthrough the first opening105dtowards the molding device101. In some embodiments, the rod104bextends towards the molding device101to provide the plunging force on the molding device101. In some embodiments, the rod104bextends and passes through the second passage104cto contact the first mold101band press the first mold101btowards the second mold101a. The rod104bcontacts the molding device101during the application of the plunging force. The plunging force is applied on the first mold101btowards the second mold101a. In some embodiments, the upward plunging force is applied to the molding device101. 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 mold101aand the first mold101bare tightly engaged with each other during the application of the plunging force. In some embodiments, the plunger104is in an extended configuration as shown inFIG.4.

In some embodiments, the method M10of injection molding method further includes locking the molding device101on the platform105abefore injection. Since the molding device101is engaged with the platform105aby the locking device103, a downward reaction force from the molding device101or the second mold base101copposing the upward plunging force is generated. As a result, the molding device101is under a higher pressure upon the application of the plunging force, compared with the molding device101maintained in the predetermined pressure (in the closed configuration) by the clamping unit102. In some embodiments, the plunging force is provided prior to and/or during an injection of the fluid or liquid from the injector105binto the mold cavity101e.

FIG.5is a schematic cross-sectional view illustrating the operation O106of the method M10in accordance with some embodiments of the present disclosure. In some embodiments, the method M10of injection molding method includes operation O106, which includes injecting a molding material from the injector105binto the mold cavity101e. In some embodiments, the fluid or liquid includes the molding material.

The fluid or liquid is discharged and flowed from the injector105binto the mold cavity101eas shown inFIG.5. In some embodiments, the fluid or liquid forms an article within the mold cavity101e. During the discharge of the fluid or liquid from the injector105binto the mold cavity101e, the plunger104keeps applying the plunging force on the molding device101, so that the second mold101akeeps engaging with the first mold101band the outlet105ckeeps engaging with the first passage101f. In some embodiments, the clamping force is applied to clamp the first mold101band the second mold101aduring the conveying of the molding device101and the injection of the fluid or liquid. During the discharge of the fluid or liquid from the injector105binto the mold cavity101e, the injector105band the outlet105care overlapped with the first passage101f, the second passage104cand the rod104bfrom a top view.

FIG.6is a schematic cross-sectional view illustrating the operation of the method M10in accordance with some embodiments of the present disclosure. In some embodiments, when the injection of the fluid or liquid into the mold cavity101eis accomplished, the injector105bis withdrawn and moved away from the molding device101as shown inFIG.6. In some embodiments, when the injection of the fluid or liquid into the mold cavity101eis accomplished, the rod104bis retracted towards the base104aand the plunging force is withdrawn by retracting the rod104b. The outlet105cis disengaged from the first passage101f, and the rod104bis moved away from the molding device101. After the withdrawn of the plunging force, the molding device101is continuously maintained in the closed configuration and under the predetermined pressure.

FIG.7is a schematic cross-sectional view illustrating the operations of the method M10in accordance with some embodiments of the present disclosure. In some embodiments, as shown inFIG.7, the method M10of injection molding method further includes conveying the molding device101away from the injection station105after the withdrawal of the injector105band the retraction of the rod104b. In some embodiments, the method M10further includes unlock the molding device101from the platform105aafter injection and before conveying the molding device101away. In some embodiments, the first locking element103aand the second locking element103bare disengaged from each other before moving the molding device101out of the injection station105.

In some embodiments, the molding device101is moved away from the platform105aby a conveying mechanism such as conveying belt, roller, etc. When the molding device101is moved out of the injection station105, the molding device101is continuously maintained in the closed configuration and under the predetermined pressure. The clamping force is continuously applied to the molding device101by the clamping unit102during or after moving the molding device101out of the injection station105.

In some embodiments, after the accomplishment of injecting the fluid or liquid from the injector105binto the mold cavity101e, the plunger104is moved away from the injection station105as shown inFIG.7. In some embodiments, after the accomplishment of injecting the fluid or liquid from the injector105binto the mold cavity101e, the molding device101and the plunger104are conveyed out of the injection station105simultaneously. In some embodiments, after the accomplishment of injecting the fluid or liquid from the injector105binto the mold cavity101e, the molding module106is moved away from the injection station105.

In some embodiments, the molding device101is moved out of the injection station105for cooling. The molding device101is cooled for a predetermined duration to form the article in the mold cavity101e. In some embodiments, the molding device101opens after the formation of the article. The clamping unit102is released to open the molding device101. The second mold101aand the first mold101bare moved away from each other, and then the article formed in the mold cavity101ecan be obtained.

As discussed above, the molding device101is required to maintain in the predetermined pressure throughout the injection molding process, except during the injection of the fluid or liquid from the injector105binto the mold cavity101e. The molding device101is required to be under a higher pressure only during the injection of the fluid or liquid from the injector105binto the mold cavity101e. In other words, it is not necessary to continuously maintain a high pressure or high force on the molding device101throughout the injection molding process. Therefore, lifespan of the molding device101can be improved or increased, energy consumed by the above injection molding system100or method can be lowered, and overall dimension or structural configuration of the molding device101can be more compact, lighter and simpler. Performance of the injection molding system or injection molding method can be more efficient and faster.

FIG.8is a flowchart showing a method M20of injection molding method in accordance with some embodiments of the present disclosure. The method M20includes several operations: (O201) 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 M20of 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 ofFIGS.9to22.

FIGS.9to22are schematic top views illustrating injection molding systems200,300. In some embodiments, the injection molding method M10as described above or illustrated inFIGS.1-7is implemented by the injection molding system200. In some embodiments, the injection molding method M20is implemented by the injection molding system200or the injection molding system300.

FIGS.9and10are schematic top views illustrating an injection molding system200of the method M20in accordance with some embodiments of the present disclosure. Initially, in some embodiments, as shown inFIG.9, the method M20of injection molding method includes step O201, which includes providing a carrier201, wherein a first molding device101-1and a second molding device101-2are held by the carrier201. In some embodiments, the method M20of injection molding method further includes step O202, which includes providing an injection station105including a platform105aand an injector105bdisposed over the platform105a, wherein the platform105aincludes a first opening105dextending through the platform105a. In some embodiments, the method M20of injection molding method includes step O203, which includes providing a plunger104disposed under the platform105a, wherein the plunger104includes a base104aand a rod104bextendable from and retractable toward the base104a. In some embodiments, the method M20of injection molding method includes step O204, which includes moving the first molding device101-1into the injection station105and disposing the first molding device101-1between the injector105band the platform105a. In some embodiments, the method M20of injection molding method includes step O205, which includes providing a plunging force to the first molding device101-1by extending the rod104bthrough the first opening105dto contact the first molding device101-1. In some embodiments, the method M20of injection molding method includes step O206, which includes injecting a molding material from the injector105binto the first molding device101-1. In some embodiments, the method M20of injection molding method includes step O207, which includes withdrawing the injector105band the rod104bfrom the first molding device101-1after injection.

In some embodiments, as shown inFIG.9, an injection molding system such as the injection molding system100shown inFIGS.1and3-7is arranged in the rotatable carrier201. In some embodiments, each of the first and second molding devices101-1,101-2is in configuration similar to the molding device101described above or illustrated inFIGS.1and3to7. In some embodiments, the injection station105is in configuration similar to the one described above or illustrated inFIGS.1and3to7. In some embodiments, the plunger104is in configuration similar to the one described above or illustrated inFIGS.1and3to7.

In some embodiments, several molding devices101-1,101-2,101-3,101-4,101-5,101-6,101-7,101-8,101-9,101-10are arranged on the carrier201. In some embodiments, the carrier201includes several holders201afor holding molding devices101-1,101-2,101-3,101-4,101-5,101-6,101-7,101-8,101-9,101-10or a part of the molding devices101-1,101-2,101-3,101-4,101-5,101-6,101-7,101-8,101-9,101-10. It is readily understood that the carrier201can include any suitable number of holders201a. In some embodiments, each of the holders201acan hold the corresponding molding devices101-1,101-2,101-3,101-4,101-5,101-6,101-7,101-8,101-9,101-10. For example as shown inFIG.9, the first and second molding devices101-1,101-2are held by two holders201arespectively. In some embodiments, the number of the holders201ais more than or equal to the number of the molding devices101-1,101-2,101-3,101-4,101-5,101-6,101-7,101-8,101-9,101-10.

The injection station105is disposed across the carrier201and several molding devices101-1,101-2,101-3,101-4,101-5,101-6,101-7,101-8,101-9,101-10are arranged on the carrier201. In some embodiments, a portion of the carrier201is disposed in the injection station105.

In some embodiments, a portion of the carrier201is disposed between the platform105aand the injector105b. The molding devices101-1,101-2,101-3,101-4,101-5,101-6,101-7,101-8,101-9,101-10are conveyed into the injection station105one by one by the rotation of the carrier201. For example, the first molding devices101-1is moved and placed on the platform105aof the injection station105, and then the injection molding method M10as described above or shown inFIGS.1and3-7is performed on the first molding device101-1. In some embodiments, the first molding device101-1is moved into the injection station105by rotation of the carrier201. In some embodiments, the carrier201is rotated in a suitable speed or by a suitable force, such that the vibration of the molding devices101-1,101-2,101-3,101-4,101-5,101-6,101-7,101-8,101-9,101-10during the conveying is minimized or even prevented. In some embodiments, the carrier201is rotated in a predetermined interval, such as an angular distance between adjacent holders201a. In some embodiments, the carrier201is rotatable about a center C1of the carrier201.

In some embodiments, the method M20includes moving the plunger104to dispose under the carrier201and the injection station105while the carrier201is stationary, or moving the carrier201to dispose the plunger104under the carrier201while the plunger104is stationary. In some embodiments, the plunger104is moved into the injection station105and disposed under the platform105abefore or after the placement of the first molding devices101-1on the platform105a. In some embodiments, the injection station105and the plunger104are movable, and the carrier201is stationary. In some embodiments, the plunger104is fixedly disposed under the carrier201before the placement of the first molding devices101-1on the platform105a. In some embodiments, the plunger104is fixedly disposed in the injection station105before the placement of the first molding devices101-1on the platform105a. In some embodiments, the platform105ais fixedly disposed under the carrier201, and the injector105bis fixedly disposed over the carrier201and overlapped with the first opening105dfrom a top view. The carrier201is movable relative to the injection station105, and the injection station105is stationary relative to the carrier201.

In some embodiments, as shown inFIG.10, the method M20of injection molding method includes step O208, which includes moving the first molding device101-1from the injection station105. Further, the method M20of injection molding method includes step O209, which includes moving the second molding device101-2into the injection station105and disposing the second molding device101-2between the injector105band the platform105a.

After the accomplishment of the injection molding method M10, in some embodiments, the first molding device101-1inside the injection station105is moved out of the injection station105by the rotation of the carrier201. Simultaneously, the second molding device101-2adjacent to the first molding device101-1is moved into the injection station105. The injection molding method M10as described above or shown inFIGS.1and3-7is performed for the second molding device101-2.

In some embodiments, the carrier201is in an annular shape. In some embodiments, the carrier201is turntable. In some embodiments, the carrier201can be rotated clockwisely or anti-clockwisely.

FIGS.11and12are schematic top views illustrating an injection molding system300of the method M20in accordance with some embodiments of the present disclosure. In some embodiments, as shown inFIGS.11and12, the injection molding system300includes a conveying belt202, and several molding devices101-1,101-2,101-3,101-4,101-5are carried by the conveying belt202. In some embodiments, the injection station105is disposed across a portion of the conveying belt202and the molding devices101-1,101-2,101-3,101-4,101-5are arranged on the conveying belt202. In some embodiments, a portion of the conveying belt202is disposed between the platform105aand the injector105b. In some embodiments, one of the molding devices101-1,101-2,101-3,101-4,101-5is disposed between the platform105aand the injector105b.

In some embodiments, as shown inFIG.11, an injection molding system such as the injection molding system100shown inFIGS.1and3-7is arranged in the conveying belt202. In some embodiments, each of the first and second molding devices101-1,101-2is in configuration similar to the molding device101described above or illustrated inFIGS.1and3to7. In some embodiments, the injection station105is in configuration similar to the one described above or illustrated inFIGS.1and3to7. In some embodiments, the plunger104is in configuration similar to the one described above or illustrated inFIGS.1and3to7.

The molding devices101-1,101-2,101-3,101-4,101-5are conveyed into the injection station105one by one by the movement of the conveying belt202. For example, the first molding device101-1is moved and placed on the platform105aof the injection station105, and then the injection molding method M10as described above or shown inFIGS.2-7is performed. In some embodiments, the plunger104is moved into the injection station105and disposed under the platform105abefore or after the placement of the first molding device101-1on the platform105a.

In some embodiments, the conveying belt202includes several holders202afor holding a molding device or a part of the molding device. It is readily understood that the conveying belt202can include any suitable number of holders202a. In some embodiments, each of the holders202acan hold the corresponding molding devices101. For example as shown inFIG.11, the first and second molding devices101-1,101-2are held by two holders202arespectively. In some embodiments, the number of the holders202ais more than or equal to the number of the molding devices101.

After the accomplishment of the injection molding method M10, as shown inFIG.12, the first molding device101-1inside the injection station105is moved out of the injection station105by the movement of the conveying belt202. Simultaneously, another molding device101such as the second molding device101-2is moved into the injection station105. The injection molding method M10as described above or shown inFIGS.2-7is performed for the second molding device101-2. In some embodiments, the conveying belt202is in a linear shape.

FIGS.13and14are schematic top views illustrating the injection molding system200of the method M20in accordance with some embodiments of the present disclosure. In some embodiments, as shown inFIGS.13and14, the injection station105is arranged outside the carrier201. In some embodiments, the plunger104is arranged outside the carrier201and overlapped with the injector105bfrom a top view. In some embodiments, as shown inFIG.13, the carrier201rotates and moves the first molding device101-1to a position adjacent to the injection station105and the plunger104. In some embodiments, as shown inFIG.14, the first molding device101-1is then conveyed from the carrier201to the injection station105by a conveying mechanism such as rollers, conveying belts or the like.

After the conveying of the first molding device101-1from the carrier201to the injection station105, the first molding device101-1, the plunger104and the injection station105is in configuration similar to the injection molding system100as described above or illustrated inFIGS.3-7. The first molding devices101-1is moved from the carrier201to the injection station105, and then placed on the platform105aof the injection station105, and then the injection molding method M10as described above or shown inFIGS.2-7is performed for the first molding device101-1. After the accomplishment of the injection molding method M10, the first molding device101-1is moved out of the injection station105and conveyed back to the carrier201as shown inFIG.13.

After the first molding device101-1is conveyed back to the carrier201, the first molding device101-1is moved away from the injection station105by the rotation of the carrier201. Simultaneously, another molding device101such as the second molding device101-2is moved toward the injection station105by the rotation of the carrier201.

FIGS.15and16are schematic top views illustrating the injection molding systems300of the method M20in accordance with some embodiments of the present disclosure. In some embodiments as shown inFIGS.15and16, the injection station105is arranged outside the conveying belt202. In some embodiments, the plunger104is arranged outside the carrier201and overlapped with the injector105bfrom a top view. In some embodiments as shown inFIG.15, the conveying belt202conveys the first molding device101-1and moves the first molding device101-1to a position adjacent to the injection station105and the plunger104. In some embodiments, as shown inFIG.16, the first molding device101-1is conveyed from the conveying belt202to the injection station105by a conveying mechanism such as rollers, conveying belts or the like.

After the conveying of the first molding device101-1from the conveying belt202to the injection station105, the first molding device101-1, the plunger104and the injection station105is in configuration similar to the injection molding system100as described above or illustrated inFIGS.1and3-7. The first molding device101-1is moved out from the conveying belt202and then placed on the platform105aof the injection station105, and then the injection molding method M10as described above or shown inFIGS.2-7is performed to the first molding device101-1. After the accomplishment of the injection molding method M10, the first molding device101-1is moved out of the injection station105and conveyed back to the conveying belt202as shown inFIG.15.

After the first molding device101-1is conveyed back to the conveying belt202, the first molding device101-1is moved away from the injection station105by the movement of the conveying belt202. Simultaneously, another molding device101such as the second molding device101-2is moved toward the conveying belt202by the movement of the conveying belt202. In some embodiments as shown inFIG.15, the molding devices101-1,101-2,101-3,101-4and101-5are linearly movable by the conveying belt202.

FIGS.17-18are schematic top views illustrating the injection molding systems200,300of the method M20in accordance with some embodiments of the present disclosure. In some embodiments as shown inFIG.17, each of the molding devices101-1,101-2,101-3,101-4,101-5,101-6,101-7,101-8,101-9,101-10and the corresponding plunger104are configured as a molding module106. In other words, the molding device101and the corresponding plunger104are moved together into the injection station105. In some embodiments, the molding device101is disposed above and overlapped with the plunger104from a top view before moving into the injection station105. In some embodiments, the second opening101gof the first mold base101dis overlapped with the rod104bof the corresponding plunger104from a top view. In some embodiments, each of the plunger104is moved together with the corresponding molding devices101-1,101-2,101-3,101-4,101-5,101-6,101-7,101-8,101-9,101-10by the rotation of the carrier201.

In some embodiments, as shown inFIG.17, the injection station105is disposed across the carrier201, and several molding modules106are arranged in the carrier201. In some embodiments, one of the molding modules106is disposed in the injection station105. The molding modules106are conveyed into the injection station105one by one by the rotation of the carrier201. For example, the first molding device101-1and the corresponding plunger104is moved and placed in the injection station105, and then the injection molding method M10as described above or shown inFIGS.2-7is performed to the molding module106including the first molding device101-1.

Similarly, in some embodiments, as shown inFIG.18, the injection station105is disposed across the conveying belt202, and several molding modules106are arranged on the conveying belt202. In some embodiments, one of the molding modules106is disposed in the injection station105. The molding modules106are conveyed into the injection station105one by one by the movement of the conveying belt202. For example, the first molding devices101-1and the corresponding plunger104is moved out from the conveying belt202and then placed on the platform105aof the injection station105, and then the injection molding method M10as described above or shown inFIGS.2-7is performed for the molding module106including the first molding device101-1.

In some embodiments, as shown inFIGS.19-20, the injection station105is arranged outside the carrier201. In some embodiments, the carrier201rotates and moves the molding module106including the first molding device101-1to a position adjacent to the injection station105. As shown inFIG.20, the molding module106including the first molding device101-1is conveyed from the carrier201to the injection station105by a conveying mechanism such as rollers, conveying belts or the like. The molding module106including the first molding device101-1is moved out from the carrier201, and then placed on the platform105aof the injection station105, and then the injection molding method M10as described above or shown inFIGS.2-7is performed for the molding module106including the first molding device101-1. After the accomplishment of the injection molding method M10, the molding module106including the first molding device101-1is moved out of the injection station105and conveyed back to the carrier201, as shown inFIG.19.

In some embodiments, as shown inFIGS.21-22, the injection station105is arranged outside the conveying belt202. In some embodiments, the conveying belt202moves the molding module106including the first molding device101-1to a position adjacent to the injection station105. As shown inFIG.22, the molding module106including the first molding device101-1is conveyed from the conveying belt202to the injection station105by a conveying mechanism such as rollers, conveying belts or the like. The molding module106including the first molding device101-1is moved out from the conveying belt202, and then placed on the platform105aof the injection station105, and then the injection molding method M10as described above or shown inFIGS.2-7is performed for the molding module106including the first molding device101-1. After the accomplishment of the injection molding method M10, the molding module106including the first molding device101-1is moved out of the injection station105and conveyed back to the conveying belt202, as shown inFIG.21.

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.

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

Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein, may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods and steps.