DESCRIPTION
Moulding process for foamed polyurethane soles
The present patent application relates to a moulding process for foamed polyurethane soles and to the soles obtained with the same process.
The use of foamed polyurethane for sole moulding is very common since the physical and mechanical characteristics of this material are very suitable to the specifications requested for this type of articles.
First of all, the low specific weight of foamed polyurethane allows for obtaining light soles, also in the case of very thick models, such as the wedge soles that are commonly used for women's footwear.
Another factor that has contributed to the success of foamed polyurethane in the production of footwear bottoms is represented by the fact that it offers good anti-slip properties and soft soles.
Last, but not least, it must be noted that the moulding process of foamed polyurethane is simple and inexpensive.
According to this process, polyurethane is poured in the bottom of the cavity of the matrix die of the mould, which is then closed and maintained closed until polyurethane has completely expanded and the part has solidified and cooled.
In order to facilitate the extraction of the part, without damaging the finish of the external walls, before pouring polyurethane, it is necessary to spray or spread a layer of "releasing" substance on the internal surface of the mould, in order to prevent polyurethane from adhering to the walls of the matrix die and to the mould cover.
Rotating platforms known as "casting wheels" are normally used for production of large series of articles. An annular series of moulds is placed on the perimeter of the platform and then opened and closed automatically by suitable actuators.
Three operating stations are installed on the casting wheel at the correct distance:
- a first station provided with means for the automatic application of the releasing substance on the internal walls of the open mould;
- a second station downstream provided with means for the automatic pouring of polyurethane in the cavity of the mould, whose cover is closed once casting has been completed;
- a third, last station placed at the correct distance from the second station and provided with means for the automatic opening of the mould from which the part is extracted, once solidification and cooling have been completed. In any case, the moulded part is first washed to remove possible stains of the releasing substance from its walls and then painted.
It must be said, however, that although low density foamed polyurethane can guarantee lightness and softness, it does not offer sufficient mechanical resistance to abrasion, being this property extremely important to prevent rapid wear of the sole heel and tread.
In view of the above limitations, soles with multi-layer structure have been devised and realised, comprising a foamed polyurethane moulded body and a moulded bottom made of rubber or any other material with good anti- wear and anti-slip properties. Being realised through the assembling of different layers, each of them moulded with a different material, these bottoms are impaired by a complex and expensive production process.
The purpose of the invention is to devise a moulding process for foamed polyurethane soles, characterised by the fact that polyurethane is poured in a thin shell that has been previously thermoformed in order to have exactly the same shape of the internal impression of the mould; it being also provided that the material has a high coefficient of elasticity and is compatible with polyurethane, meaning that it can physically and/or chemically "bind" with the polyurethane casting, in order to form a monolithic sole characterised by the fact that it presents a surface layer of material with good anti-wear and anti-slip properties on the lower and lateral surface.
According to the process of the invention a thin sheet of polyurethane-
compatible material with good anti-wear and anti-slip properties is laid and tightened between the mould and the matrix die.
Once the mould has been closed, the air contained in the internal cavity is extracted completely, extracting it both above and below the thin sheet tightened between the matrix die and cover.
Should air be extracted from below only, the sheet would tend to adhere against the internal walls of the matrix die, with the risk of occluding the extraction holes located on the internal walls of the impression before the air is completely extracted. Once vacuum has been created above and below the sheet tightened between the matrix die and the cover, hot pressurised air is gradually introduced in the space above the sheet.
It must be noted that the air temperature must cause the softening of the sheet that, because of the air pressure, stretches against the bottom and walls of the matrix die, thus perfectly adhering to its profile.
In other words, it can be said that the combined action of high temperature and the high pressure of the air that is gradually introduced in the mould results in the progressive thermoforming of the sheet, which takes the shape of a shell perfectly adhering to the internal walls of the impression of the matrix die of the mould.
Then the hot air is discharged and the mould is opened in order to pour polyurethane in the shell.
It must be said, however, that before pouring the polyurethane, the shell must be heated again, for example by means of infrared lamps, in order to bring it to a physical state that is close to fusion and favours the best and most complete "welding" between the polyurethane casting and the shell.
The sole obtained with the process of the invention does not need to be washed or painted, since the external surface has the colour and surface finish of the aforementioned sheet. To this end it must be noted that the painting of the sheet, by means of silk-screening or holography processes, permits to reproduce the surface finish of any material, such as wood, cork, leather, marble, materials that are
often imitated in foamed polyurethane bottoms, with very low costs and high accuracy.
By using a sheet of transparent material and painting it on its upper side, that is the side that remains inside the shell, it will be possible to preserve the initial colour and surface finish of the sole over time, since natural wear caused by abrasion will affect the external side of the sheet.
The sheet can be continuously supplied from a roll located near the mould and automatically cut with suitable size.
For major clarity the description of the invention continues with reference to the enclosed drawings, which are intended for purposes of illustration and not in a limiting sense, whereby:
- figures 1 to 8 show the different operating phases of the moulding process of the invention aimed to obtain a sole with homogeneous colour and surface finish both on tread and side; - figures 9 to 18 show the different operating phases of the moulding process of the invention aimed to obtain a sole with two surfaces of different finish or colour.
It must be noted that the figures show the mould and the moulded sole sectioned with a transversal vertical plane. With reference to figures 1 to 8, the process of the invention in its simplest implementation mode makes use of an ordinary mould for foamed polyurethane soles, with the only characteristic that it has one or more holes (1a and 2a) respectively on the cover (1) and the matrix die (2), used to introduce or extract air in/from the internal cavity of the mould. The sequence of the moulding cycle is as follows:
- laying of a thin flexible sheet (F) on the matrix die (2) to close the opening of the impression (2b) of the matrix die (2), as shown in fig. 1 ;
- closing of the mould with tightening of the sheet (F) between the cover (1 ) and the matrix die (2), as shown in fig. 2; - extraction of the air contained in the cavity of the mould through the holes (1a and 2a), as shown in fig. 3;
- suspension of air extraction through the holes (2a) and gradual introduction
of hot pressurised air into the mould through the holes (1a) in order to soften the sheet (F) and thermoform it with the shape of a shell (G) that perfectly adheres to the walls of the impression (2b), as shown in fig. 4;
- discharge of hot air through the holes (1a), as shown in fig. 5; - possible heating, with the mould open, of the shell (G) to maintain it at a temperature value close to fusion, as shown in fig. 6;
- pouring of polyurethane (P) into the shell (G) and closing of the mould, as shown in fig. 7;
- extraction of the part, once solidification and cooling of the foamed polyurethane have been completed, as shown in fig. 8.
The sole (S) obtained with the process of the invention is characterised by the fact that it has a monolithic structure formed by a moulded foamed polyurethane body (100) having a surface layer (101) of different material with good anti-wear and anti-slip properties on the lower and lateral surface. A sole with two colours or two different surface finishes (such as false rubber tread and false wooden side) can be obtained by using a mould that comprises a ring (3) provided with holes (3a) for the passage of air placed between the cover (1) and the matrix die (2), as shown in the second group of figures from 9 to 18. In this case the sequence of the moulding cycle is as follows:
- laying of a first thin flexible sheet (F1) on the matrix die (2) to close the opening of the impression (2b) of the matrix die (2), as shown in fig. 9;
- tightening of the sheet (F1) between the matrix die (2) and the ring (3), as shown in fig. 10; - laying of a second thin flexible sheet (F2) with different finish compared to the sheet (F1) on the ring (3), as shown in fig. 11 ;
- closing of the mould with tightening of the sheet (F2) between the cover (1) and the ring (3), as shown in fig. 12;
- extraction of the air contained in the cavity of the mould through the holes (1a, 2a and 3a), as shown in fig. 13;
- suspension of air extraction through the holes (2a and 3a) and gradual introduction of hot pressurised air into the mould through the holes (1 a) in
order to soften the sheets (F1 and F2) and thermoform them simultaneously with the shape of a shell (G1) that perfectly adheres to the walls of the impression (2b), as shown in fig. 14;
- discharge of hot air through the holes (1a), as shown in fig. 15; - possible heating, with the mould open, of the shell (G1) to maintain it at a temperature value close to fusion, as shown in fig. 16;
- pouring of polyurethane (P) into the shell (G1) and closing of the mould, as shown in fig. 17;
- extraction of the part, once solidification and cooling of the foamed polyurethane have been completed, as shown in fig. 18.
The sole (S1) obtained with the process of the invention is characterised by the fact that it has a monolithic structure formed by a moulded foamed polyurethane body (100) contained in a shell (G1) with two different surface finishes. The tread of the sole (S1) has the finish of the first sheet (F1), with a separation line (D) on the lateral sides between two overlapped bands, of which the upper band has the finish of the second sheet (F2) and the lower band has the finish of the first sheet (F1).
In figures from 8 to 18 letter (L) indicates the borders of the sheets (F or F1 or F2) that must be cut. Cutting can be carried out after the part has been extracted or when the part is still contained in the mould. In the latter case, the mould must be provided with an ordinary cutting device.
The heating, with the mould open, of the shells (G or G1) can be carried out by means of infrared lamps (I) or with any other suitable source of heat.
According to the process of the invention the sheets (F, F1 and F2) are made of a material having a high coefficient of elasticity (percentage ultimate elongation higher than 500%), good anti-wear and anti-slip properties, which is compatible with foamed polyurethane, meaning that it can physically and/or chemically bind with polyurethane.
The sheets (F, F1 and F2) can be, for example, of thermoplastic polyurethane with thickness ranging from a few tens of micron (such as in the
case of the sheet F2 located on the sides of the sole) to a few tens of millimetre (such in the case of the sheet F1 located on the tread of the sole).