CN114102931A - 制造塑性部件的方法、塑性部件、中底和鞋 - Google Patents
制造塑性部件的方法、塑性部件、中底和鞋 Download PDFInfo
- Publication number
- CN114102931A CN114102931A CN202111227912.9A CN202111227912A CN114102931A CN 114102931 A CN114102931 A CN 114102931A CN 202111227912 A CN202111227912 A CN 202111227912A CN 114102931 A CN114102931 A CN 114102931A
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- Prior art keywords
- mold
- plastic part
- midsole
- expanded particles
- mould
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Links
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Abstract
本发明涉及一种用于制造塑性部件(135)的增强的方法,该塑性部件(135)特别是运动服的缓冲元件,该方法包含:以预定量打开模具(100)到装填位置,其中该模具包含至少两个模具构件(110,112),其中模具打开的量影响模具可利用的装填容积;将包含膨胀粒子(130)的材料装填到装填容积中;闭合模具到闭合位置,其中在模具闭合过程中,模具构件一起移动的局部距离Δz大体上是塑性部件(135)的局部厚度z的连续函数Δz=Δz(z);通过闭合模具压缩膨胀粒子;以及,至少熔合膨胀粒子的表面以模制该塑性部件。
Description
本申请是申请日为2017年11月24日、申请号为201780073742.9、发明名称为“制造塑性部件的方法、塑性部件、中底和鞋”的中国发明专利申请的分案申请。
技术领域
本发明涉及一种制造塑性部件——特别是运动服的缓冲元件——的方法,用这样的方法制造的塑性部件,以及中底和鞋。
背景技术
现今,塑性部件在许多技术领域和日常生活中起到了基本作用。作为例子,提及航空和航天工业以及汽车工业。在这些领域中,塑性部件可以例如充当冲击保护元件,例如缓冲器,或者它们可以用于制造面板元件、座位套、扶手等。塑性部件还可以用于包装工业,例如用于包装敏感和易损商品来用于运送。
在全部的这些示例性应用领域中,如果塑性部件包含尽可能小的重量,但是同时是足够回弹性的,则是有利的。具体地,对于塑性部件用于冲击保护或者用于安全包裹商品来说,塑性部件还应当包含相对于吹动或者击打来说良好的缓冲和减震特性。在上下文中,发泡塑性材料是现有技术中已知的,如膨胀聚苯乙烯-例如在商标名或者下获自BASF。
膨胀塑性材料还已经用于制造运动服的缓冲元件,例如制造运动鞋的鞋底。
在鞋制造领域,特别是在高性能运动鞋设计中,存在强烈需求去改进鞋的单独部件的材料特性,例如部件的挠性、耐磨性、刚度、压缩强度和/或回弹性,以及另外的物理和化学材料特性。
例如,可能期望增强运动鞋中底的材料特性,以提供在鞋的使用过程中更高的性能,提供中底的改进的穿着舒适性和/或增加的寿命,而同时改进制造的容易性。
具体地,已经考虑了使用膨胀热塑性聚氨酯(expanded thermoplasticpolyurethane,eTPU)粒子,所述粒子通过供应蒸汽形式的热来熔合在一起或者通过使用黏合剂材料连接在一起,所述黏合剂材料如DE102012206094A1和DE102011108744B1所述。
此外,现有技术文献EP2649896B1提供了改进的鞋和鞋的内底(所述鞋特别是运动鞋)及其制造方法。一方面,提供了鞋(特别是运动鞋)的鞋底,鞋底设置有至少第一表面区域和第二表面区域,其中第一表面区域包含eTPU。
另外,EP3114954A1涉及一种制造用于鞋(特别是运动鞋)的鞋底的方法,包含:将模具的可移动构件打开到预定的程度,将eTPU粒子装填到该模具中,根据要制造的鞋底的形状来减少该模具的容积,以及将蒸汽供给到eTPU,其中该鞋底的机械特性至少部分地取决于该模具在装填过程中打开的程度。
但是,可以进一步改进现有技术所述的制造方法的不同方面。
所以本发明要解决的一个问题是进一步改进包含膨胀粒子——例如eTPU或者膨胀的聚醚嵌段酰胺(expanded polyether-block-amide,ePEBA)——的塑性部件的制造方法,来改进该塑性部件的材料特性和/或制造容易性。
此外,期望将这样的包含膨胀粒子的增强的塑性部件引入鞋的中底中和/或鞋中。
发明内容
通过本申请权利要求的主题至少部分地实现了上述目标。
在第一实施例中,本发明提供一种制造塑性部件的方法,所述塑性部件特别是运动服的缓冲元件,该方法包含:以预定量打开模具到装填位置的步骤,其中,该模具包含至少两个模具构件,模具打开的量影响模具可利用的装填容积;将包含膨胀粒子的材料装填到装填容积的步骤;闭合模具到闭合位置的步骤,其中,在模具闭合过程中,模具构件在模具的不同区域中一起移动了不同的距离;通过闭合模具压缩膨胀粒子的步骤;以及,至少熔合膨胀粒子的表面以模制该塑性部件的步骤。
膨胀粒子有时候也称作“发泡粒子”,并且模制的塑性部件因此有时候称作“粒子发泡部件”。可以用于提及这样的膨胀粒子的其他术语例如包括“珠料”或者“粒料”。
例如,所述方法允许改进在塑性部件制造过程中对于膨胀粒子局部压缩的控制,以使得该塑性部件可以表现出优异的材料特性。塑性部件的材料特性(例如密度和/或压缩刚度)可以迎合特定应用或者用途。例如,用于运动鞋的塑性部件的局部密度/压缩刚度可以优化和适应于不同类型的运动活动,例如网球、跑步、足球、篮球等,和/或优化用于不同的表面,例如森林小径、沥青、混凝土、沙子、草地、硬木等,和/或适应于个体穿戴者的解剖学特征和/或步态。
此外,这样的增强的塑性部件可以容易地整合到其他类型的运动服中,例如具有整合的缓冲元件的服饰和/或凉鞋、滑雪靴、雪地靴、高尔夫鞋以及各种各样的保护性运动装备例如手套(特别是棒球手套、守门员手套和/或拳击手套)、护胫、护膝和/或护肘、头盔、护背等等。
此外,这样的增强的塑性部件还可以整合到种类繁多的运动装备中,例如滑雪橇、滑雪板、溜冰板、冲浪板、拳击靶、健身器材等等。
在本发明的另一实施例中,模具构件一起移动的不同的距离局部影响膨胀粒子的压缩度。
在另一实施例中,至少对于模具的一个区域,模具构件一起移动的不同距离与模制的塑性部件中的厚度分布相关,优选基本上成比例。
例如,可以可能确保基本上恒定的压缩度和因此模制的塑性部件中基本上恒定的密度。在这方面,以及对于本申请的其余部分来说,术语“基本上”应当定义为“处于常规的制造公差内”。
例如,对于下面这样的塑性部件来说可能会期望恒定的密度:厚度不均匀(例如楔形部件,例如鞋底),但还需要某些密度相关的物理材料特性是基本上均匀的。
在本发明的另一实施例中,膨胀粒子通过热蒸汽和/或电磁辐射至少部分地熔合。
例如,这种实施例允许不依赖于黏结剂或者胶合剂模制塑性部件,并且还允许将熔合膨胀粒子表面所需的热量均匀分布在该模具的整个容积内。
如果使用电磁辐射,则该膨胀粒子不曝露于热蒸汽存在的湿气中,这会是某些实施例所期望的。此外,用电磁辐射加热膨胀粒子是更加能量有效的,并且允许更精确地控制熔合过程的动力学。
对本领域技术人员来说显然本发明还与其他常规模制技术(例如压塑等)是相容的。
在本发明的另一实施例中,在闭合模具过程中,至少一个模具构件绕偏心设置的旋转轴枢转,其中该旋转轴优选连接到安装板,其中优选在该安装板和该至少一个模具构件之间设置不同长度的可变形的隔离器元件。
在这方面,术语“偏心(eccentrically)”是相对于模具的横向中心线来定义的。
例如,这种实施例提供了一种简单方式执行至少两个模具构件在闭合模具过程中在模具的不同区域中一起移动的期望的不同距离。
在本发明的另一实施例中,至少一个该模具构件包含几个单独的子构件,其中对于每个子构件,可以单独控制模具构件一起移动的不同的距离。
这种实施例允许将不同的压缩方案应用于模具不同部分中的膨胀粒子。例如,在该模具的一部分中可能会期望均匀的压缩,在第二部分中可能会期望非均匀的压缩。这会适宜于生产鞋的中底,中底包含在中足和后足区段中的基本上楔形的部分以及在前足区段中的基本上均匀的部分。
在本发明的另一实施例中,在用膨胀粒子装填模具容积的步骤之后,密封该模具,以使得所述方法的其余步骤可以空间上在与装填模具步骤的不同位置处进行。
例如,这种实施例允许在塑性部件的多站式生产线的专用装填站装填模具。装填站可以单独优化以用于用膨胀粒子装填模具。在装填后,密封的模具可以运输到生产线的另外的工艺站,例如电磁熔合站,电磁熔合站可以单独优化以用于有效地电磁结合膨胀粒子。通过局部分离随后的制造步骤以及将模具从一个工艺站运输到接下来的站,执行本发明所提供的方法的制造线可以被进一步优化。
在另一实施例中,本发明提供一种塑性部件,特别是包含膨胀粒子的运动服缓冲元件,其中该塑性部件的局部密度和/或局部压缩刚度取决于模制该塑性部件过程中膨胀粒子的局部压缩度。
例如,这样的包含膨胀粒子的塑性部件的依赖密度的机械特性可以根据与具体应用相关的规格来设计,例如用于不同种类的运动鞋(例如篮球、网球和或者户外跑鞋)的中底。
本发明更具体的实施例涉及一种增强的塑性部件,其中该塑性部件的局部密度和/或局部压缩刚度在塑性部件的至少一部分中,优选在整个塑性部件中,是基本上恒定的
另外的实施例涉及一种增强的塑性部件,其中该塑性部件的局部密度和/或局部压缩刚度与塑性部件的至少一部分中的厚度分布相关,优选基本上成比例。
例如,以此方式可以制造这样的塑性部件,其表现出均匀的机械特性,例如压缩刚度和密度。此外,塑性部件可以以令人期望的方式制造来生产改进的运动鞋的中底。
在另一实施例中,本发明提供一种塑性部件,其包含下述材料中的一种或多种:膨胀热塑性聚氨酯(expanded thermoplastic polyurethane,eTPU);膨胀聚酰胺(expandedpolyamide,ePA);膨胀聚醚嵌段酰胺(expanded poly ether-block-amide,ePEBA);膨胀聚交酯(expanded polylactide,ePLA);膨胀聚对苯二甲酸乙二醇酯(expandedpolyethylene terephthalate,ePET);膨胀聚对苯二甲酸丁二醇酯(expandedpolybutylene terephthalate,ePBT);膨胀热塑性聚酯醚弹性体(expandedthermoplastic polyester ether elastomer,eTPEE)。
关于膨胀粒子(例如膨胀聚合物粒料)进一步的细节在本申请人的DE102014216992A1、WO2016030026A1和WO2016030333A1中给出。
例如,eTPU(或者类似的膨胀粒子)优异的材料特性允许设计运动服的增强的缓冲元件。例如,包含eTPU的运动鞋的中底提供了增强的穿着舒适性和优异的跑步特性。具体地,这样的中底在冲击后立即松弛到它的初始形式,这归因于它大的回弹,这种回弹取决于eTPU材料的回弹性。结果,存储在中底的弹性形变中的冲击能重新投射到穿用者的腿部并且由此增强了跑步性能。
在另一实施例中,本发明提供一种鞋的中底,所述鞋特别是运动鞋,该中底包含根据本发明的以及根据本发明所提供的任何方法生产的塑性部件。
在另一实施例中,本发明提供一种鞋的中底,所述鞋特别是运动鞋,该中底包含膨胀粒子,其中该中底的局部密度在基本上整个中底范围内的变化小于20%,优选小于15%,更优选小于10%,以及最优选小于5%。
中底不同区段中的局部密度可以例如通过本领域已知的任何相关方法来测定,所述相关方法还允许可再现地测定包含膨胀粒子(例如膨胀TPU)的塑性部件的密度。
附加地或者替代性地,该中底可以表现出这样的压缩刚度,其在基本上整个中底范围内的变化小于20%,优选小于15%,更优选小于10%,以及最优选小于5%。
附加地或者替代性地,该中底可以包含根据本发明所提供的任何方法制造的塑性部件。
中底不同区段中的压缩刚度可以通过本领域已知的任何相关方法来测定,所述相关方法还允许可再现地测定包含膨胀粒子(例如膨胀TPU)的塑性部件的压缩刚度。一个这样的例子是根据ISO 844:2014“Rigid cellular plastics--Determination ofcompression properties(硬质泡沫塑料——压缩性能试验方法)”的测试方法。
在另一实施例中,本发明提供一种鞋,特别是运动鞋,该鞋包含根据上述本发明实施例的中底。
这样的运动鞋,例如可以提供优异的回弹、穿着舒适性和震动缓冲,因此确保了减少穿用者所经历的疲劳以及增加使用过程中的跑步和/或跳跃性能。
附图说明
在下面参考附图来更详细地描述本发明的实施例。这些附图示出了:
图1a:根据本发明一实施例的处于装填位置的模具的示意性纵向剖面图;
图1b:根据本发明一实施例的处于闭合位置的模具的示意性纵向剖面图;
图1c:根据本发明一实施例的处于闭合位置及在熔合膨胀粒子过程中的模具的示意性纵向剖面图;
图1d:根据本发明一实施例的处于塑性部件从中脱模的过程中的模具的示意性纵向剖面图;
图2:适用于根据本发明方法的示意性模具设计;
图3a:根据本发明一实施例的运动鞋的中底的底视图;
图3b:根据本发明一实施例的运动鞋的中底的侧视图;
图3c:根据本发明另一实施例的运动鞋的中底的底视图;
图4:根据本发明所生产的中底的密度和通过膨胀粒子的常规模制技术所生产的中底的密度变化的比较。
具体实施方式
在下面,参考制造楔形塑性部件并且特别是运动鞋的中底来更详细地描述本发明的示例性实施例。但是,要理解的是本发明不限于这样的具体实施例,而是可以应用于其他类型的,特别是打算用作一般运动服和运动装备缓冲元件的塑性部件。此外,虽然具体特征的组合在下面是涉及本发明的某些实施例来描述的,但是要理解的是本公开不限于这样的实施例。换言之,不是全部用来实现本发明的特征都必须出现,并且可以通过将一实施例的某些特征与另一实施例的一个或多个特征组合来改变这些实施例。
图1a描绘了设置在装填位置的根据本发明第一实施例的示意性模具设计的纵向剖面图,在此期间膨胀粒子130(例如eTPU粒子)装填到该模具100a中。该装填位置也可以称作开缝(crack gap)位置,该模具因此称作开缝模具。
在一些实施例中,膨胀粒子可以全部表现出基本上相同的尺寸和几何形状,其中,在其他实施例中,膨胀粒子的尺寸和几何形状可以不同,在另一些实施例中膨胀粒子的尺寸和几何形状可以明显不同。在另一些实施例中,膨胀粒子可以包含不同材料的粒子并且特别是不同聚合物的混合物的粒子,以精细调节塑性部件的材料特性。
膨胀粒子可以还包含有利于在模具内形成塑性部件的黏结剂和/或胶合剂。此外,膨胀粒子可以包含吸收能量的材料,吸收能量的材料例如会促进能量从外部施加的电磁场转移到模具内的膨胀粒子。
在所提出的实施例中,模具100a设置在膨胀粒子130的存储器(未示出)下方,以使得膨胀粒子130至少部分地通过重力引导装填到模具容积中。
例如,模具100a可以在装填站被膨胀粒子130的存储器装填,其中该存储器可以设置在装填站的模具位置的上方。由于存储器设置在模具100a位置的上方,因此膨胀粒子130流可以主要依靠重力引导到模具100a中,无需使用增压空气或者类似手段来运输膨胀粒子130。以类似方式,模制的塑性部件可以无需专用的移除装置来从模具中脱模。两种效果都降低了制造技术复杂性和提高了效率。
替代性地或者附加地,可以通过例如用增压气体和/或增压空气运行的运输和装填机构来将膨胀粒子130运输到模具100a及装填到模具容积中。使用基于增压气体和/或空气的装填机构可以降低装填模具容积所需的时间,因此增加生产吞吐量。
模具100a可以包含至少两个模具构件110、112,这两个模具构件110、112在模具100a的装填位置相比于闭合位置(参见图1b)可以相对于彼此分开更远。结果,装填位置的模具容积大于闭合位置的模具容积。
典型地,在装填位置时用膨胀粒子基本上完全装填该模具容积,其中膨胀粒子保持为基本上处于非压缩态。处于装填位置的模具容积大于在模具100a的闭合位置形成的模制的塑性部件135的体积这一事实有利于避免在塑性部件135内形成不期望的空隙,特别是减少了表面上和沿着塑性部件135边缘的不期望的空隙的数目。
此外,装填处于具有较大模具容积的装填位置的模具100a,使得在开口150(穿过它来装填膨胀粒子)附近产生了较小的压缩。
在闭合模具100a之前,还可以改变装填容积,因此允许更高或者更低总量的膨胀粒子在模具内。
图1b描绘了——在已经用膨胀粒子130装填模具容积后以及在已经通过将半模110、112从装填位置移动到闭合位置而将膨胀粒子130在模具100b内压缩之后——配置在闭合位置的图1a的模具100b。
归因于膨胀粒子130在闭合模具100b过程中所经历的压缩,模具容积基本上用膨胀粒子均匀装填,这些膨胀粒子在闭合位置处于压缩态。
在图1b所示的实施例中,所述半模朝着彼此移动的局部距离取决于塑性部件的厚度,因此膨胀粒子在闭合位置的压缩度沿着塑性部件的范围是基本上恒定的。
这可以通过控制模具构件110、112一起移动的局部距离Δz以使得Δz与塑性部件的厚度z基本上成比例(即Δz=αz,具有比例常数α)来实现。如果压缩度λ定义为局部距离Δz和塑性部件的局部厚度z之比(即λ=Δz/z),则很显然压缩度λ是恒定的,并且等于比例常数α。
这样的压缩度控制可以通过开缝模具来实施,该模具设置为,使得至少两个模具构件被设置为相对于彼此可枢转(pivotable)。具体地,模具构件之一或者二者可以安装在偏心枢轴处,以使得通过该模具构件之一绕偏心枢轴进行旋转运动并由此均匀压缩膨胀粒子,来实现基本恒定的压缩度。
对于本发明的其他应用来说,可以期望产生这样的塑性部件,表现出与塑性部件135的局部厚度z成比例的压缩度λ(即λ=βz)。这可以通过控制模具构件110、112一起移动的局部距离Δz以使得Δz基本上是塑性部件135的局部厚度z的二次函数(即Δz=βz2)来实现。
对于另一些的实施例,可以期望产生这样的部件,表现出压缩度λ与塑性部件135的局部厚度z成反比例(即λ=γ/z)。这可以通过控制该模具构件110、112一起移动的局部距离Δz以使得Δz是恒定的来实现(即Δz=γ)。
通常,塑性部件135的局部厚度z取决于塑性部件在x-y平面中的准确位置,即局部厚度z是在x-y平面内的位置的分段连续函数z=z(x,y)。
在闭模过程中模具构件110、112一起移动的局部距离Δz转而可以大体上也是局部厚度的连续函数,即Δz=Δz(z)。在这种方式中,局部压缩度λ=Δz/z也变成了在x-y平面内的位置的分段连续函数。
如果例如Δz是厚度z的次数为n的多项式,则压缩度是局部厚度z的次数为n-1多项式。上述观点可以容易地推广到其他类型的函数例如三角函数或者指数。
某些模具构造可以允许作为x-y平面内位置的准连续函数来直接控制压缩度λ。这可以通过调整模具构件110、112中的至少一个以使得它包含多个单独可控的模具元件(相对于塑性部件135的范围,模具元件是小的)来实现。这种技术例如可以允许运动鞋的中底的压缩度单独适应于个体穿用者的足部的解剖学形状。
模具100b可以还包含用于闭合开口150(在装填位置,穿过开口150将膨胀粒子130装填到模具容积)的装置160。在一些实施例中,用于闭合开口150的装置160可以整合到模具100b中。在其他实施例中,用于闭合开口150的装置160也可以与模具100b分离,可以拆下以用于装填,并在装填后连接上。在更进一步的实施例中,可以通过模具构件110、112之一的外表面部分来从模具容积的内部闭合开口150。
图1c描绘了在熔合膨胀粒子过程中图1a和图1b的模具。
在一些实施例中,膨胀粒子130可以通过以下方式熔合在一起,将膨胀粒子加热到高于一各别温度,从而膨胀粒子的表面部分熔融在一起并形成基本上完全连接的塑性部件135。
在一实施例中,可以通过供入模具容积中的热蒸汽来供应热量。
在一些实施例中,可以通过加热模具的一些部分(如两个模具构件110、112)来另外提供热量。
在另一些实施例中,可以通过电磁辐射——例如RF、MW、激光、UV或者X射线辐射——来提供热量。模具构件110、112可以充当电容器极板,其可以连接到高功率RF或者MW放大器上。
为了增强从电磁辐射到膨胀粒子130的能量转移,膨胀粒子130可以包含至少一种能量吸收材料,该能量吸收材料在该电磁辐射所处的电磁光谱的相应部分(电磁辐射供应用来加热和熔合膨胀粒子130的能量)中表现出大的吸收剖面。
在一些实施例中,模具100c可以在闭合位置密封。在模具100c密封后,它可以从装填站(装填站用于用膨胀粒子130装填模具容积)运输到专用熔合站,在这里发生熔合膨胀粒子130,例如通过RF或者MW加热和/或蒸汽加热。
这样的方法可以允许设计灵活的和高度自动化的生产线,该生产线使用模块化工艺站,例如装填站、压缩站、熔合站、冷却站、脱模站。生产工艺的模块化设计能够独立地优化生产工艺的每个站的设计和运行。
图1d描绘了图1a-1c的模具100d处于这样的配置中:已经完成模制塑性部件135,并且该塑性部件135正在从模具100d中脱模。在一些实施例中,定向该模具100d,以使得塑性部件可以通过重力作用从模具100d中掉出,这样不需要存在专用的移除装置。但是在其他实施例中可以使用专用的移除装置。
在用膨胀粒子装填模具后模具可以已经密封的一些实施例中,可以在不同位置对塑性部件进行脱模,然后装填模具和/或熔合膨胀粒子。
对于一些实施例,该模具100d可以配置为,使得两个模具构件110、112连接到模具组件,以使得它们能够在塑性部件135模制后容易地打开,并且充分冷却以方便脱模。
在图1a-1d中示意性描绘的生产过程可以配置为,使得在模制的构件135从模具100d脱模后(如图1d所示),模具100d可以例如通过增压空气来清洁,并且可以运回装填站(参见图1a),从而该生产过程可以重新开始。
在全部过程步骤是在相同位置进行(即,在联合的装填、压缩、熔合、脱模站)的其他实施例中,该模具100d仅仅需要被放回到图1a所示的装填配置,以重新开始所述生产过程。
图2描绘了一种具体的模具设计,其允许执行本发明所提供的至少一些制造方法。具体地,该模具200包含两个模具构件210和212,其中第一模具构件212可以绕偏心设置的旋转轴280枢转。该旋转轴转而连接到安装板270,使得当安装板280朝着另一模具构件210推压时,通过压缩装填到模具容积中的膨胀粒子230所形成的压力,第一模具构件212绕旋转轴280枢转。
偏心旋转轴相对于模具的横向中心线偏心设置,当第一模具构件212绕偏心设置的旋转轴280枢转时,产生了不同的依赖位置的两个模具构件210和212一起移动的距离。
为了产生楔形塑性部件,可以在安装板270和第一模具构件212之间设置可变形的隔离器290,例如弹簧元件。
可变形的隔离器290确保了,两个模具构件210和212在设置于装填位置期间用膨胀粒子230装填模具200的过程中,形成楔形装填容积。
偏心设置的旋转轴280与可变形的隔离器290(在沿着安装板270的不同位置上可以表现出不同的尺寸)的组合允许调节在装填位置两个模具构件210和212之间的角度。
结果,这两个模具构件在模具闭合过程中在模具200的不同区域中一起移动了不同的距离,这产生了沿着模具200纵向范围的取决于位置的压缩度。
图3a描绘了根据本发明所生产的示例性中底300的底视图,该中底可以包含前足区段310、中足区段320和后足区段330。
在一些实施例中,全部区段表现出沿着中底300连续或者不连续变化的不同的厚度。它们组合也是可能的,例如中底300可以设置为,使得厚度从前足310到中足区段320连续变化,以及从中足区段320到后足区段330不连续变化。
根据本发明的中底300还可以在各自的区段中表现出恒定或者变化的密度。如同厚度分布那样,该密度也可以从一个区段到相邻区段连续和或不连续地变化。
图3b描绘了图3a的中底300的侧视图。所示的实施例表现出连续变化的厚度分布和不恒定的压缩度。具体地,前足区段310中的膨胀粒子的压缩态大于中足320和后足区段330。这例如会在后足330和中足区段320中产生大于前足区段310的回弹,因为它会是某些类型的运动鞋所期望的。
但是对于其他类型的运动鞋,还会期望前足区段310中的膨胀粒子可以压缩到与中足320和/或后足区段330中的膨胀粒子相同的程度。这可以例如通过本发明的实施例之一来实现,该实施例提供了基本上与中底300的厚度分布成比例的压缩距离。
图3c描绘了图3a的中底300的底视图,在基本上中底300的整个范围内表现出基本上恒定的压缩度和/或基本上恒定的密度。图3c所示的实施例已经通过从中底300切掉三个基本上圆柱形样品片FF、MF、RF而进行了改变,其中每个样品片分别是从中底300的前足区段310、中足区段320和后足区段330切掉的。
为了确定沿着中底300范围的局部密度的变化,可以通过适于测量包含膨胀粒子的塑性部件密度的密度测量方法来测定每个样品片FF、MF、RF的密度。
在需要中底300更详细的密度轮廓的情况中,可以降低样品片的尺寸和/或可以增加能够从中底上切掉的样品片的数目。
图4示出了在根据本发明所生产的中底上进行的密度测量的结果,该中底类似于图3c所示的那一个,并且使用类似于图3c所示形状的样品片。
图4显示了从根据本发明提供的方法生产的中底300的前足区段FF、中足区段MF和后足区段RF所取样品片每个的密度。具体地,为了生产用于图4所示密度测量的测试样品中底,已经使用了类似于图2所描绘的模具设计。
因此,膨胀粒子已经在测试样品中底的模制过程中被基本上均匀地压缩。
结果,中底的局部密度在后足区段和中足区段之间以及在后足区段和前足区段之间的变化小于4%。具体地,在测量的统计学不确定性之内在中足和前足区段之间基本上没能测定到密度变化。
所示结果已经通过平均5个中底300的测试样品的测量值获得,所述中底使用相同制造方法、相同模具和相同标称工艺参数生产。
例如,中底的平均密度可以是250kg/m3-400kg/m3,优选275kg/m3-375kg/m3,更优选300kg/m3-350kg/m3,以及最优选315kg/m3-335kg/m3。
但是,对本领域技术人员来说显然上述和图4所示的绝对值仅仅是示例性的。中底300的绝对密度可以取决于不同的参数,例如膨胀粒子的密度、用于生产膨胀粒子的聚合物的类型、膨胀粒子在制造过程中所经历的膨胀度、膨胀粒子在模制中底300的过程中所经历的压缩度以及中底300所需的压缩刚度。
本发明与现有技术已知的模制技术(如下面的在先申请所述)相比产生了局部密度沿着基本上中底300的整个范围的较大的变化。
Claims (15)
1.制造塑性部件(135)的方法,所述塑性部件(135)特别是运动服的缓冲元件,所述方法包含:
a.以预定量打开模具(100)到装填位置;其中所述模具(100)包含至少两个模具构件(110,112),以及其中所述模具(100)打开的量影响所述模具(100)的可利用的装填容积;
b.将包含膨胀粒子(130)的材料装填到所述装填容积中;
c.闭合所述模具(100)到闭合位置;
其中,在所述模具(100)闭合过程中,所述模具构件(110,112)一起移动的局部距离Δz大体上是所述塑性部件(135)的局部厚度z的连续函数Δz=Δz(z);
d.通过闭合所述模具(100)压缩所述膨胀粒子(130);
e.至少熔合所述膨胀粒子(130)的表面以模制所述塑性部件(135)。
2.根据权利要求1所述的方法,其中,在所述模具(100)闭合过程中,所述模具构件(110,112)在所述模具(100)的不同区域中一起移动不同的距离(140)。
3.根据权利要求2所述的方法,其中所述不同的距离(140)局部影响所述膨胀粒子(130)的压缩度。
4.根据权利要求2或3所述的方法,
其中,至少对于所述模具的一个区段,所述不同的距离(140)是与模制的塑性部件(135)中的厚度分布相关的,优选是基本上成比例的。
5.根据前述任一项权利要求所述的方法,
其中所述膨胀粒子(130)是通过热蒸汽和/或电磁辐射部分地熔合在一起的。
6.根据前述任一项权利要求所述的方法,
其中,在所述模具(200)闭合过程中,至少一个模具构件(212)绕偏心设置的旋转轴(280)枢转;
其中所述旋转轴(280)优选连接到安装板(270)上;以及,其中优选在所述安装板(270)和所述至少一个模具构件(212)之间设置不同长度的可变形的隔离器元件(290)。
7.根据前述任一项权利要求所述的方法,
其中至少一个模具构件(110,112)包含几个单独的子构件,以及,其中所述模具构件(110,112)一起移动的不同距离(140)对于每个子构件可以被单独控制。
8.根据前述任一项权利要求所述的方法,
其中,在用膨胀粒子(130)装填所述模具容积的步骤之后,密封所述模具(100),以使得所述方法的其余步骤可以在与装填模具(100)的步骤不同的位置上进行。
9.根据权利要求1-8中任一项所述方法制造的塑性部件(135),特别是运动鞋的缓冲元件,包含:
a.膨胀粒子(130)
b.其中所述塑性部件(135)的局部密度和/或局部压缩刚度取决于模制部件(135)过程中膨胀粒子(130)的局部压缩度。
10.根据权利要求9所述的塑性部件(135),
其中,所述塑性部件(135)的局部密度和/或局部压缩刚度在塑性部件(135)的至少一部分中,优选在整个塑性部件(135)中,是基本恒定的。
11.根据权利要求9-10中任一项所述的塑性部件(135),其中所述膨胀粒子(130)包含下述材料中的一种或多种:膨胀热塑性聚氨酯eTPU;膨胀聚酰胺ePA;膨胀聚醚嵌段酰胺ePEBA;膨胀聚交酯ePLA;膨胀聚对苯二甲酸乙二醇酯ePET;膨胀聚对苯二甲酸丁二醇酯ePBT;膨胀热塑性聚酯醚弹性体eTPEE。
12.鞋的中底(300),所述鞋特别是运动鞋,所述中底(300)包含根据权利要求9-11中任一项所述的和根据权利要求1-8中任一项所生产的塑性部件(135)。
13.鞋的中底(300),所述鞋特别是运动鞋,所述中底(300)包含用于根据权利要求9-11中任一项所述的塑性部件(135)和根据权利要求1-8中任一项所述的方法的膨胀粒子,其中,所述中底(300)的局部密度在基本上中底(300)的整个范围内的变化小于20%,优选小于15%,更优选小于10%,以及最优选小于5%。
14.根据权利要求12或者13任一项所述的中底(300),其中所述中底(300)的压缩刚度在基本上中底(300)的整个范围内的变化小于20%,优选小于15%,更优选小于10%,以及最优选小于5%。
15.鞋,特别是运动鞋,包含根据权利要求12-14中任一项所述的中底(300)。
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