Process for manufacturing a multi-layered sole directly on the upper and machine operating with said process

Abstract

A process for manufacturing a multi-layered sole directly on the upper, of the type that employs the technique known as direct injection on the upper, by which soles are made of a plastic material and consist of a plurality of layers with different colour, density, softness and physical-mechanical properties. Said layers form at least an external sole, called outsole, an internal sole, called insole that adheres and extends only partially or totally on the surface of the upper, and an intermediate sole, called midsole, that is intended to hold the other two above-said soles. Said process provides for the use of a single mould which is brought, when suitably equipped, in a well-defined sequence, in front of at least three distinct injectors (I.sub.1, I.sub.2, I.sub.3) in order to obtain, also in sequence, by at least a first moulding operation (P.sub.1) the lower portion of the sole, i.e. the outsole, by at least a second moulding operation (P.sub.2) the upper part of the sole, i.e. the insole and by at least a third moulding operation (P.sub.3) the midsole.

Claims

1. A process for manufacturing a multi-layered sole directly on an upper employing a technique known as direct injection on the upper, by which soles (S) are made of a plastic material and consist of a plurality of layers with different colour, density, softness, said layers forming at least an external sole, called outsole (S.sub.1), an internal sole, called insole (S.sub.2) that adheres and extends only partially or totally on a surface of the upper (T), and an intermediate sole, called midsole (S.sub.3), that is intended to hold the other two above-said soles (S.sub.1, S.sub.2), said process providing for use of a single mould which is brought, when suitably equipped, in a well-defined sequence, in front of at least three distinct injectors (I.sub.1, I.sub.2, I.sub.3) in order to obtain, also in sequence, by at least a first moulding operation (P.sub.1) a lower portion of the sole, i.e. the outsole (S.sub.1), by at least a second moulding operation (P.sub.2) a upper part of the sole, i.e. the insole (S.sub.2) and by at least a third moulding operation (P.sub.3) the midsole (S.sub.3), wherein, said process employs the single mould consisting of a number of components removably connected to each other in order to be able to be suitably equipped with respect to the injector of the at least three distinct injectors (I.sub.1, I.sub.2, I.sub.3), which components comprise a support, rotating about an axis (X) of its central pin on which a radial arm, ending with a form related to the upper (T), and an opposite radial arm, ending with a disc, are removably hooked, two opposed side half-rings, two upper opposed half-rings and a base.

2. The process for manufacturing a multi-layered sole directly on the upper according to claim 1, wherein it provides a cavity in the mould, in order to obtain the outsole (S.sub.1), that is defined by the disc, the base and the two opposed side half-rings, mutually close to each other.

3. The process for manufacturing a multi-layered sole directly on the upper according to claim 1, wherein it provides a cavity in the mould, in order to obtain the insole (S.sub.2), that is defined by a form related to the upper (T) and by the two opposed upper half-rings, mutually close to each other.

4. The process for manufacturing a multi-layered sole directly on the upper according to claim 1, wherein it provides a cavity in the mould, in order to obtain the intermediate sole (S.sub.3), that is defined by the form related to the upper (T) and the insole (S.sub.2), by the base related to the outsole (S.sub.1) and by the two opposed side half-rings, mutually close to each other.

5. The process for manufacturing a multi-layered sole directly on the upper according to claim 1, that uses a machine equipped with a plurality of moulds, mounted on a carousel (G), that rotates about a vertical axis (Y) and where there are three moulding stations (P.sub.1, P.sub.2, P.sub.3), in each of which there is one of the single moulds that is sequentially arranged, once suitably equipped, in front of injectors (I.sub.1, I.sub.2, I.sub.3), to progressively carry out the moulding, at the station (P.sub.1) of the outsole (S.sub.1), at the station (P.sub.2) of the insole (S.sub.2) and at the station (P.sub.3) of the midsole (S.sub.3), respectively, wherein said process provides the following steps: at the first moulding station (P.sub.1), where the outsole (S.sub.1) is made, once the mould is placed in front of the injector (I.sub.1), from an open mould condition, the support with the disc thereof is lowered, the base is lifted and the two opposed side half-rings are closed, so as to create a cavity inside which the plastic material is injected, through the injector (I.sub.1) or by direct casting so as to form the outsole (S.sub.1); at the second moulding station (P.sub.2), where the insole (S.sub.2) is made, by the rotation of the carousel (G) the mould is placed in front of the injector (I.sub.2) and, from the open mould condition, the support is lowered and rotated by 180, so as to place the form related to the upper (T) in a lower position and the two opposed upper half-rings are closed so as to create a cavity inside which the plastic material is injected, through the injector (I.sub.2) so as to form the insole (S.sub.2); at the third moulding station (P.sub.3), where the midsole (S.sub.3) is made, by the rotation of the carousel (G) the mould is placed in front of the injector (I.sub.3) and, from the open mould condition, the support and the form thereof related to the upper (T) and the insole (S.sub.2) are lowered, the base related to the outsole (S.sub.1) is lifted and the two opposed side half-rings are closed, so as to create a cavity inside which the plastic material is injected through the injector (I.sub.3), so as to form the midsole (S.sub.3), in order to complete the sole (S); after hardening the injected plastic material, by the further rotation of the carousel (G), the mould is brought in front of an operator (M) and from the open mould condition the support is rotated by 180 so as to bring the upper (T) provided with the sole (S) upwards, so that it is easily accessible for the above-said operator (M), who removes a completed footwear (C) from the form and puts a new upper (T) on the above-said form.

Description

(1) The invention will be better defined by the description of a possible embodiment thereof, given only by way of non-limiting example, in which:

(2) FIGS. 1, 2, 3 show views of an upper provided with the multi-layer sole, the carousel with the three moulding stations and the exploded components of the mould, respectively;

(3) FIG. 4 shows views for the manufacture of the outsole;

(4) FIG. 5 shows views relating to the manufacture of the insole;

(5) FIG. 6 shows views relating to the manufacture of the midsole;

(6) FIG. 7 shows views relating to the unloading of the complete shoe and the loading of a new upper.

(7) As shown in FIG. 1, the shoe indicated with reference C comprises a upper T provided with a sole S made of plastic material, obtainable with the method according to the invention, which consists of three layers or soles, of different color and/or different mechanical-physical properties, the outermost sole S.sub.1 constitutes the outsole, the innermost sole S.sub.2 constitutes the insole that adheres and extends only partially or totally on the surface of the upper T and the intermediate sole S.sub.3 which constitutes the midsole, which has the function of retaining the two other aforementioned soles.

(8) As shown in FIG. 2, the sole S is made with a machine, where the moulds 100 are mounted on a carousel G rotating around the vertical axis Y, where there are three moulding stations, indicated with references P.sub.1, P.sub.2, P.sub.3, in each of which there is a mould 100.1, 100.2 and 100.3 which, after being suitably equipped, is arranged sequentially in front of the respective injectors, indicated by references I.sub.1, I.sub.2, I.sub.3, to carry out the moulding, in progression, respectively, in the station P.sub.1 of the outsole S.sub.1, in the station P.sub.2 of the insole S.sub.2 and in the station P.sub.3 of the intermediate sole S.sub.3.

(9) On the carousel there is also a station, indicated with reference P.sub.4, where the operator takes the completed C shoe from the mould and fits a new upper T on the form.

(10) As shown in FIG. 3, the mould 100 consists of a series of components 100.1, 100.2 and 100.3 removably connected to each other so as to be suitably equipped in relation to the type of corresponding injector I.sub.1, I.sub.2, I.sub.3, as better specified in the following description.

(11) Specifically, the mould 100 comprises a support 1, rotating around the axis X of its central pin, on which a radial arm 2, ending with a form 3 related to the upper T, and an opposite radial arm 4, ending with the disc 5, are removably hooked; two opposed side half-rings 6.1 and 6.2, two upper opposed half-rings 7.1 and 7.2 and a base 8.

(12) The process according to the invention is implemented with the machine according to the invention as follows.

(13) As can be seen in FIG. 4, at the first moulding station P.sub.1, where the outsole S.sub.1 is made, once the mould 100.1 is placed in front of the injector I.sub.1, from the open mould condition (ref. 4a), the support with the disc thereof is lowered, the base 8 is lifted and the two opposed side half-rings 6.1 and 6.2 are closed, so as to create a cavity 10 (ref. 4b) inside which the plastic material is injected, through the injector I1 or by direct casting or by other techniques, so as to form the outsole S.sub.1 (ref. 4c).

(14) As can be seen in FIG. 5, at the second moulding station P.sub.2, where the insole S.sub.2 is made, by the rotation of the carousel G the mould 100.2 is placed in front of the injector I.sub.2 and, from the open mould condition (ref. 5a), the support 1 is lowered and rotated by 180, so as to place the form 3 related to the upper T in a lower position and the two opposed upper half-rings 7.1 and 7.2 are closed so as to create a cavity 20 (ref. 5b) inside which the plastic material is injected, through the injector I.sub.2 so as to form the insole S.sub.2 (ref. 5c).

(15) As can be seen in FIG. 6, at the third moulding station P.sub.3, where the midsole S.sub.3 is made, by the rotation of the carousel G the mould 100.3 is placed in front of the injector I.sub.3 and, from the open mould condition (ref. 6a), the support 1 and the form thereof 3 related to the upper T and the insole S.sub.2 are lowered, the base 8 related to the outsole S.sub.1 is lifted and the two opposed side half-rings 6.1 and 6.2 are closed, so as to create a cavity 30 (ref. 6b) inside which the plastic material is injected through the injector I.sub.3, so as to form the midsole S.sub.3, in order to complete the sole S (ref. 6c).

(16) Finally, as can be seen in FIG. 7, a fourth station P.sub.4 is provided where, after hardening the injected plastic material, by the further rotation of the carousel G, the mould 100 is brought in front of an operator M; from the open mould condition (pos. 7a), the support 1 is rotated by 180 so as to bring the upper T provided with the sole S (ref. 7b) upwards, so that it is easily accessible for the above-said operator M, who removes the footwear C from the form 3 and puts a new upper T on the above-said form 3.

(17) In particular, as shown in FIG. 2, depending on the size of the carousel G, which depends on the number of mounted moulds 100, the aforementioned station can be positioned upstream (ref. P.sub.4.1) or downstream (pos. P.sub.4.2) of the first station P.sub.1.

(18) From the foregoing it is clear that the intended objects of rapidity in terms of execution of the process and of the cost-effectiveness in the manufacture and use of the machine have been fully achieved.

(19) Of course, the technical design details and the components used, known in the prior art and in evolution, may be the most varied, provided that everything falls within the inventive concept defined by the following claims.