The present invention provides for a mould set for fabrication of an EPS pallet, a process for making the mould set for fabrication of the EPS pallet, and a process for fabricating the EPS pallet using the mould set. The mould set includes a modular platform mould and a leg mould configured to fabricate a platform section and plurality of leg support sections of the EPS pallet, respectively. The modular platform mould includes a modularity unit which enables alternation of dimension of hollow space which is configured to receive feed of polystyrene beads and thereby enabling moulding of the platform section of varying dimensions from a single mould. The one or more leg support sections are affixed to bottom side of the platform section at predefined locations, based on weight bearing capacity and position of lifting, to form the EPS pallet. The easy customization into various sizes as per requirement using a single mould structure reduces requirement of hoarding various moulds for different dimensions of EPS pallet, thereby significantly reducing the cost of moulding operations.

The present invention provides for a mould set for fabrication of an EPS pallet, a process for making the mould set for fabrication of the EPS pallet, and a process for fabricating the EPS pallet using the mould set. The mould set includes a modular platform mould and a leg mould configured to fabricate a platform section and plurality of leg support sections of the EPS pallet, respectively. The modular platform mould includes a modularity unit which enables alternation of dimension of hollow space which is configured to receive feed of polystyrene beads and thereby enabling moulding of the platform section of varying dimensions from a single mould. The one or more leg support sections are affixed to bottom side of the platform section at predefined locations, based on weight bearing capacity and position of lifting, to form the EPS pallet. The easy customization into various sizes as per requirement using a single mould structure reduces requirement of hoarding various moulds for different dimensions of EPS pallet, thereby significantly reducing the cost of moulding operations.

The invention relates to a mold (200) for producing a foam cladding (120) made of plastic on a planar component (100) or for producing a foamed plastic part (120), comprising a mixing head (300) for producing liquid plastic from at least two components, at least one first cavity (240) for receiving the plastic in order to form the foam cladding (120) or to produce the foamed plastic part (120), a sprue channel (210) for connecting the mixing head (300) to the at least one first cavity (240), and a further cavity (220), which is formed at the transition of the sprue channel (210) to the first cavity (240) and widens the sprue channel (210). For automated cutting of a tag-like sprue, which would otherwise adhere to the foam cladding, the invention provides that a sprue cutter (400) having at least one slide (410) is movably mounted on the mold (200), which slide can be moved by means of at least one actuating cylinder (450) in the direction of the sprue channel (210) toward the first cavity (240) and, in an end position of the movement of the slide, closes off the first cavity (240) from the sprue channel (210) and/or from the further cavity (220) by means of at least one edge (414) and/or contour (412).

The invention relates to a mold (200) for producing a foam cladding (120) made of plastic on a planar component (100) or for producing a foamed plastic part (120), comprising a mixing head (300) for producing liquid plastic from at least two components, at least one first cavity (240) for receiving the plastic in order to form the foam cladding (120) or to produce the foamed plastic part (120), a sprue channel (210) for connecting the mixing head (300) to the at least one first cavity (240), and a further cavity (220), which is formed at the transition of the sprue channel (210) to the first cavity (240) and widens the sprue channel (210). For automated cutting of a tag-like sprue, which would otherwise adhere to the foam cladding, the invention provides that a sprue cutter (400) having at least one slide (410) is movably mounted on the mold (200), which slide can be moved by means of at least one actuating cylinder (450) in the direction of the sprue channel (210) toward the first cavity (240) and, in an end position of the movement of the slide, closes off the first cavity (240) from the sprue channel (210) and/or from the further cavity (220) by means of at least one edge (414) and/or contour (412).

In a molding die, movable die elements are respectively received in die element receiving holes formed in a frame plate. An end surface of the frame plate, which faces a cavity at a location that is other than locations of the die element receiving holes, forms a frame portion compression surface. An end surface of each movable die element, which faces the cavity, forms a split compression surface. Die element drive devices respectively drive the split compression surfaces of the movable die elements. A whole compression plate commonly supports an opposite end part of the frame plate and opposite end parts of the movable die elements, which are opposite from the cavity. When the whole compression plate is moved forward, the whole compression plate integrally drives the frame plate and the movable die elements forward. A whole drive device drives the whole compression plate.

A midsole molding apparatus which enables production of a high-quality midsole is provided. The apparatus includes a through hole, which passes laterally through a midsole used for a shoe, to be integrally formed, preventing traces of forming the through hole from being left in the through hole and on the periphery of the through hole and a shaft mold crossing the inner space of upper and lower molds, forming extending portions such that the ends of the shaft mold extend beyond the boundary of the inner space, and seating the extending portions in press recesses of the upper and lower molds to seal the insides of the molds so as to prevent raw material from leaking from inside the molds when foaming and forming a midsole, to prevent parting lines and burrs from forming on the inner surface of the through hole passing laterally through the midsole.

A midsole molding apparatus which enables production of a high-quality midsole is provided. The apparatus includes a through hole, which passes laterally through a midsole used for a shoe, to be integrally formed, preventing traces of forming the through hole from being left in the through hole and on the periphery of the through hole and a shaft mold crossing the inner space of upper and lower molds, forming extending portions such that the ends of the shaft mold extend beyond the boundary of the inner space, and seating the extending portions in press recesses of the upper and lower molds to seal the insides of the molds so as to prevent raw material from leaking from inside the molds when foaming and forming a midsole, to prevent parting lines and burrs from forming on the inner surface of the through hole passing laterally through the midsole.

A foam molding method includes: sealing a core material and a skin material with a sealing part; and molding a foam layer on the inside of the sealing part. The sealing of the core material and the skin material with the sealing part includes sealing the core material and the skin material so that the sealing part includes a self sealing part for which an edge part of the skin material is housed in a recess provided in the core material, a clamp sealing part sealed by clamping the core material and the edge part of the skin material by foam molding molds, and a crimp sealing part arranged in a switchover part between the clamp sealing part and the self sealing part, and sealed by crimping the edge part of the skin material to the core material.

A foam molding method includes: sealing a core material and a skin material with a sealing part; and molding a foam layer on the inside of the sealing part. The sealing of the core material and the skin material with the sealing part includes sealing the core material and the skin material so that the sealing part includes a self sealing part for which an edge part of the skin material is housed in a recess provided in the core material, a clamp sealing part sealed by clamping the core material and the edge part of the skin material by foam molding molds, and a crimp sealing part arranged in a switchover part between the clamp sealing part and the self sealing part, and sealed by crimping the edge part of the skin material to the core material.

Described herein is a process for preparing a molded article including at least one structured surface, said process including applying a composition, preferably a foam material, into a mold having at least one structured inner surface and curing said composition to provide the molded structured article. The inner surfaces of the mold can be coated with a coating composition to obtain molded structured articles further including a flexible and durable coating layer. The present invention also relates to a structured molded article, preferably a shoe sole, which is obtained by the process.