A MOULD DEVICE FOR DIRECT INJECTION MOULDING OF FOOTWEAR, A SYSTEM COMPRISING SUCH A MOULD DEVICE AND A DIRECT INJECTION MOULDING SYSTEM

Abstract

A mold device for production of footwear by direct injection molding includes a first side mold, a second side mold, and a bottom mold. The first side mold and the second side mold are configured to be movable laterally in relation to each other and the bottom mold is configured to be movable vertically in relation to the first side mold and the second side mold. The first side mold, the second side mold, and the bottom mold are configured to define at least part of a mold cavity The mold device further includes a last holding device.

Claims

1. A mould device for production of footwear by direct injection moulding, the mould device comprising: a first side mould; a second side mould; a bottom mould; and a last holding device, wherein said first side mould and said second side mould are configured to be movable laterally in relation to each other, wherein said bottom mould is configured to be movable vertically in relation to said first side mould and said second side mould, and wherein said first side mould, said second side mould, and said bottom mould are configured to define at least part of a mould cavity for said direct injection moulding of footwear.

2. The mould device according to claim 1, wherein said last holding device comprises a last positioning arm fixed to each of said first side mould and said second side mould, said last positioning arms being designed for gripping a last or a last holder holding a last.

3. The mould device according to claim 2, wherein said last positioning arms are designed for gripping a part of said last or said last holder, when said first side mould and said second side mould are abutting each other.

4. (canceled)

5. The mould device according to claim 2, wherein the last holding device is configured to provide a fixation for relative movement of the last or the last holder at least in an upwards direction.

6. The mould device according to claim 1, wherein said last holding device is removably fixed to said first side mould and said second side mould.

7. (canceled)

8. The mould device according to claim 1, wherein said mould device further comprises a mould lock comprising a mould locking device for locking said first side mould and said second side mould together in a relative position, abutting each other.

9. (canceled)

10. The mould device according to claim 1, wherein said mould device further comprises a bottom mould lock for locking said bottom mould relative to said first side mould or said second side mould.

11.-16. (canceled)

17. The mould device according to claim 1, wherein said mould device further comprises an identifier, associated with one or more parts of the mould device.

18. A system for production of footwear by direct injection moulding, said system comprising: a mould device including: a first side mould, a second side mould, a bottom mould, and a last holding device; and a last or a last holder for holding said last, wherein said first side mould and said second side mould are configured to be movable laterally in relation to each other, wherein said bottom mould is configured to be movable vertically in relation to said first side mould and said second side mould, and wherein said first side mould, said second side mould, and said bottom mould define at least part of a mould cavity for said direct injection moulding of footwear.

19. The system according to claim 18, said system further comprising an automated handler for positioning said last or said last holder, said last carrying a footwear upper, at a predetermined position relative to the mould device, where said first side mould and said second side mould are at least a predetermined distance laterally from each other, wherein said last holding device is configured to hold said last, by said last holder, when said first side mould and said second side mould are in a position abutting each other.

20.-21. (canceled)

22. The system according to 18, wherein the system further comprises injection moulding equipment for performing the direct injection moulding of a sole part in said mould cavity.

23. A direct injection moulding system for performing at least part of a direct injection moulding manufacturing of footwear, said system comprising: at least one mould device defining at least partly a mould cavity in combination with a last carrying a footwear upper; and a conveyor system for conveying said at least one mould device between a plurality of stations, said at least one mould device comprising a last holding device, which is configured for holding said last carrying said footwear upper at least when performing the direct injection moulding of a sole part onto said footwear upper, wherein the system is configured for conveying said at least one mould device from one station to a subsequent station of said plurality of stations with said last holding device being an integrated part of said mould device.

24. The system according to claim 23, wherein said mould device comprises mould parts that are movable relative to each other, wherein the system is configured for effecting a relative movement of at least one of said mould parts at at least one of said plurality of stations, wherein the mould parts include: a first side mould, a second side mould, and a bottom mould, wherein the first side mould and the second side mould are configured to be movable laterally in relation to each other, and wherein the bottom mould is configured to be movable vertically in relation to the first side mould and the second side mould.

25. (canceled)

26. The system according to claim 23, wherein said last holding device comprises a last positioning arm fixed to each of said first side mould and said second side mould, said last positioning arms being designed for gripping said last or a last holder holding said last.

27.-29. (canceled)

30. The system according to claim 23, wherein the system further comprises a pre-injection station including an automated handler for introducing and positioning said last carrying said footwear upper to said mould device.

31.-36. (canceled)

37. The system according to claim 23, wherein said conveyor system for comprises at least one carrier beam, which is configured to reciprocate in an at least partly horizontal direction with a fixed horizontal stroke.

38. The system according to claim 37, wherein said at least one carrier beam comprises a plurality of carrier sub-beams, each having at least one vertically oriented carrier sub-beam pin.

39. The system according to claim 38, wherein said at least one vertically oriented carrier sub-beam pin is configured for being moved in the vertical direction.

40. The system according to claim 23, wherein at least one of said plurality of stations comprises two carrier plates each having at least one vertically oriented carrier pin, which carrier plates are configured for being moved away from each other and towards each other in the direction of said at least one carrier beam.

41.-43. (canceled)

44. The system according to claim 37, wherein said conveyor system is configured modularly with a length of said at least one carrier beam corresponding to a number of stations.

45.-52. (canceled)

Description

THE FIGURES

[0111] The invention will be explained in further detail below with reference to the figures of which

[0112] FIG. 1 shows a schematically illustrated embodiment of a mould device, seen in a cross-sectional view and in an open state, for direct injection moulding of footwear,

[0113] FIG. 2 shows the schematically illustrated mould device, seen in a cross-sectional view as shown in FIG. 1, but in connection with a last for direct injection moulding of footwear,

[0114] FIG. 3 shows the schematically illustrated mould device and last, seen in a cross-sectional view as shown in FIG. 2, where the side moulds have been moved together whereby a last holder of the last has been gripped by the mould device,

[0115] FIG. 4 shows the schematically illustrated mould device and last, seen in a cross-sectional view as shown in FIG. 3, and where the bottom mould has been lifted and a moulding material has been injected in a mould cavity,

[0116] FIG. 5 shows the schematically illustrated mould device and last, seen in a cross-sectional view as shown in FIG. 4, but in a closed state with the bottom mould in an upper position and with the injected material forming a footwear sole,

[0117] FIG. 6 corresponds to FIG. 3, showing the schematically illustrated mould device and last, seen in a cross-sectional view, where the side moulds have been moved together to grip a last holder of the last, and where a further embodiment of a last holding device has been illustrated,

[0118] FIGS. 7a,b show an embodiment of a mould device having a last holding device, seen in a perspective view,

[0119] FIG. 8 shows correspondingly an embodiment of a mould device, seen in a perspective view, where the side moulds are in an open state,

[0120] FIGS. 9a-c are flow diagrams illustrating possible flows using a mould device according to embodiments,

[0121] FIG. 10 is a schematic view from above of a direct injection moulding system comprising a plurality of stations and wherein mould devices are transferred from one station to the next during manufacturing, and

[0122] FIG. 11 is a corresponding schematic view from above of a direct injection moulding system illustrating modularity options of the stations and groups of stations.

DETAILED DESCRIPTION

[0123] With reference to FIG. 1 an embodiment of a mould device 2 will be explained in detail in the following. The mould device 2 for direct injection moulding of footwear is schematically illustrated in FIG. 1, where it is seen in a cross-sectional view and in an open state.

[0124] The mould device 2 may be made out of metal, for example aluminium by e.g. CNC machinery and may as shown in FIG. 1 comprise a first side mould 4, a second side mould 6 and a bottom mould 8, which are arranged in such a manner that the mould 2 may be opened and closed, e.g. by the first side mould 4 and the second side mould 6 being able to be moved laterally in horizontal directions as indicated with the arrows A and B, respectively, and by the bottom mould 8 being arranged to be moved in the vertical direction as indicated with the arrow C. It is noted that additionally the side moulds 4 and 6 may be moved angularly, e.g. flipped or tilted, which will be elucidated later on, e.g. in connection with the mould device being used in a conveying system such as a walking beam system. Such a flipping or tilting of the side moulds is indicated in FIG. 1 by the curved arrows A and B, which are depicted in dash lines.

[0125] As shown in FIG. 1, the first side mould 4 and the second side mould 6 may be provided with a first side surface 10 and a second side surface 12, respectively, that for example have been made during the e.g. CNC milling, and which generally define a desired form of a side part of a shoe sole to be moulded. Further, the bottom mould 8 may correspondingly be provided with a bottom inner surface 14, which have been made during the e.g. CNC milling and which generally has a form corresponding to a desired form of the underside of the shoe sole to be moulded, e.g. defining a mould cavity 40.

[0126] As furthermore illustrated in FIG. 1, the mould device 2 may be arranged with a last holding device 16 that may comprise two last positioning arms 18, e.g. one placed in connection with each of the side moulds 4 and 6, respectively. The last holding device 16, e.g. the last positioning arms 18 may be arranged such as it will appear in greater detail from the following that at a distance above the first side mould 4 and the second side mould 6, e.g. at their upper ends, they will cooperate to hold a last or a last holder, when the first side mould 4 and the second side mould 6 are moved together in abutting positions. To this means, the last positioning arms 18 may comprise schematically illustrated arm gripper parts 26 that will cooperate with last gripper parts that will be explained further on. Alternatively, a separate part may serve for carrying the e.g. last positioning arms 18 for holding a last or a last holder.

[0127] The last positioning arms 18 may be connected to the first side mould 4 and the second side mould 6 by fixing devices 24, e.g. threaded connections, bolt connections, clamp connections or the like. The fixing devices 24 may be releasable, e.g. in order to exchange the last positioning arms 18 for arms being e.g. longer or shorter.

[0128] As further shown in FIG. 2, which corresponds to FIG. 1, the schematically illustrated mould device 2 is here seen in connection with a last 20 for use in e.g. direct injection moulding of footwear. The last 20, which is also seen in a cross-sectional view, is connected to a last holder 22 and the last is carrying a footwear upper 30. The last 20 with the footwear upper 30 can be moved in various directions including downwards in relation to the mould 2 as indicated with the arrow D. The last 20 with the footwear upper 30 may be moved towards the mould device 2 and positioned in relation to this by means of an automated handler, an automated positioning device, e.g. an industrial robot, etc. (not shown in FIG. 2). It will be understood that when performing such a step, it is required that the mould 2 is in an at least partly open state in order to allow the last 20 to move into the mould 2. Hereafter the mould 2 may be closed, thus forming a mould cavity 40 between the footwear upper 30, the first side mould 4, the second side mould 6 and the bottom mould 8. As explained above, the last 20 and the last holder 22 has been positioned such that the last holding device 16, e.g. the last positioning arms 18 will grip the last 20 or the last holder 22, e.g. by gripping the last gripper parts 28 that correspond to the arm gripper parts 26, whereby these parts will be fixed to each other.

[0129] This has been illustrated in FIG. 3, where the side moulds 4 and 6 have been moved into an abutting relationship and where it is shown that a mould cavity 40 is formed by the first side surface 10, the second side surface 12, the part of the upper 30 facing downwards, e.g. restricted by the contact with the lip 32 of the first and second side surface and the bottom mould surface 14, which in FIG. 3 is illustrated moving upwards, before having reached an end position.

[0130] It will be understood that the mould 2 at a point will be attached to injection moulding equipment (not shown in here), by means of which injection material is injected into the mould cavity, where it comes into contact with the first side surface 10, the second side surface 12, the bottom mould surface 14 and the bottom parts of the footwear upper 30. It will be understood that the lip 32 and the contact surfaces of the upper 30 are forced into contact so that the flow of the injection material cannot pass out of the mould cavity via the contact surfaces and the lip 32. When the injected material has taken the shape of the mould cavity, it is being cured.

[0131] As shown in FIG. 4, the injection material may be introduced into the mould cavity 40, e.g. by introducing it to the bottom inner surface 14 as injected material 60 prior to the closing of the mould device 2, where the mould device 2 subsequently may be closed, e.g. by closing also the bottom mould 8, allowing the injected material to expand to fill the mould cavity 40 and to bond to the lower part of the upper 30.

[0132] FIG. 5 shows the stage where the bottom mould 8 has been moved upwards as indicated in the vertical direction C, where the bottom mould 8 abuts the protrusions of the first side mould 4 and the second side mould 6, thus closing the mould cavity 40. When the mould device 2 is closed, the mould cavity 40 is closed to the surrounding environment, ensuring that the injected material 60, when expanded, has taken the shape of the mould cavity 40 and forms the footwear sole 62.

[0133] In FIG. 5 it is furthermore indicated that the bottom mould 8 has been locked to the first side mould 4 and the second side mould 6 by bottom mould locking taps 54, that may have been moved to perform the locking action by e.g. actuator means (not shown in FIG. 5). Hereby, it is achieved that the bottom mould 8 will be held in place, thereby obviating e.g. a constant application of a force to the bottom mould. The schematically illustrated bottom mould locking taps 54 as shown in FIG. 5 are exemplary illustrations only and various other configurations may be applied, including separate parts that are locked to the mould parts, etc.

[0134] In principle, when the injected material 60 has cured, the bottom mould 8, when unlocked, may be moved downwards in the direction C, while simultaneously the first side mould 4 and the second side mould 6 may be moved in a horizontal movement as indicated by the arrows A and B, respectively, thereby opening the footwear injection mould. As it will be explained further on, the first side mould 4 and the second side mould 6 may be locked to each other, therefore requiring an unlocking prior to opening and before the last 20 and the upper 30 with the sole 62 attached may be removed from the mould device 2.

[0135] It is noted that the injected material may be for forming a midsole and that an outsole (not shown in FIG. 5) in such a case has been provided in the bottom mould in advance.

[0136] FIG. 6 corresponds essentially to FIG. 3, in that FIG. 6 shows the schematically illustrated mould device 2 and last 20, seen in a cross-sectional view, where the side moulds 4 and 6 have been moved together to grip a last holder 22 of the last 20. A further embodiment of the last holding device 16 has however been illustrated, where the last positioning arms 18 are connected to a last holding device base 70, which may e.g. comprise a base part on each side of the mould device 2, e.g. associated with each of the first and second side moulds 4 and 6. The last holding device base 70 may be fixed permanently to the mould parts, but may instead be connected in a removable manner, e.g. by means such as base connectors 72 that are indicated in FIG. 6, e.g. taps, screws, other threaded connectors, clamps or the like. It will be apparent to a skilled person that other variations are possible, including the configuration of the last holding device base 70 and/or the last positioning arms 18.

[0137] Also, it is noted that the bottom mould 8 may be connected to other mould parts in a removable manner.

[0138] To further illustrate an embodiment of a mould device 2 having a last holding device 16, FIG. 7a shows such a mould device in a perspective view. Here, it is shown that the last positioning arms 18 may be fixed to each side mould by fixing devices 24 in the form of threaded bolts. Further, an exemplary embodiment of the arm gripper parts 26 is indicated here. It should be noted that the last positioning arms 18 may have recesses 36 near the top in order to clear the last or the last holder, when this is introduced and gripped.

[0139] Further, it is shown in FIG. 7a that the upper part of the mould cavity 40 as defined by the side moulds may comprise a lip 32 for contacting the footwear upper on the last. Also, it is indicated that the mould device 2 comprises an injection channel 34 at one end, which injection channel 34 may be arranged in the parts of the side moulds 4, 6 that are in abutment. Furthermore, a mould locking device 50 is shown, which facilitates the locking of the two side moulds to each other. The mould locking device 50 is shown at one end, but one may be placed at each end of the mould device 2. It is noted that the mould locking device 50 is illustrated in the figures in a schematic manner to illustrate the functionality and that various designs, configurations, locations of the lock, etc., including use of various activators and the like may be applied as it will be apparent to a skilled person.

[0140] FIG. 7b shows in a perspective view an embodiment of a mould device 2 having a last holding device 16 essentially corresponding to the embodiment shown in FIG. 7a, but where a last 20 carried by a last holder 22 is gripped by the last positioning arms 18, e.g. by the arm gripper parts 26 having gripped the last gripper parts 28.

[0141] FIG. 8 shows correspondingly an embodiment of a mould device 2, seen in a perspective view, where the side moulds 4, 6 are moved away from each other such that the mould device 2 is in an open state. Here, it is furthermore indicated that the mould locking device 50 is cooperating with a locking tap 52 on each of the side moulds 4, 6. The locking may be effected by moving the mould locking device 50 down, when the side moulds 4, 6 are in abutment, and correspondingly the mould device 2 may be unlocked by moving mould locking device 50 upwards, e.g. a indicated by the double-arrow.

[0142] FIG. 9a-9c are flow diagrams illustrating possible flows in a part of a footwear production using a mould device or a system according to an embodiment.

[0143] FIG. 9a is a flow diagram where at 100 a mould device is received and subsequently opened 102, e.g. unlocked, if it, e.g. its parts, have been provided in locked form, and the side moulds with corresponding last positioning arms are moved to be spaced from each other. Possibly, preparation 104 of the mould device may be performed, e.g. application of anti-stick agents, lubrication or the like to the surfaces of the side moulds and the bottom mould in case this has not been taken care of in an earlier stage. It is noted that in connection with the preparation 104 of the mould device, the side moulds may be flipped individually, e.g. tilted away from each other in order to make more space for the operations, provide access to the inner faces, etc. This may in particular be the case, when the mould device is arranged in a transport system such as a walking beam system (as will be explained later), where the mould devices possibly may be arranged relatively close together.

[0144] A last is provided at 106, which last has been applied with a footwear upper matching the piece of footwear that is being manufactured. The last is being positioned at step 108 in relation to the mould device and thus also in relation to the last positioning arms, whereby the last (or a last holder fixed to the last) will be gripped and held, when the mould, e.g. the side moulds, are closed at 110 and locked to each other.

[0145] At this stage, the moulding material may be injected at 112, while e.g. a bottom mould of the mould device is still being moved upwards, until it at step 114 is locked to the rest of the mould device. At this stage, the various parts of the mould device are locked to each other, thus obviating any external means for holding it together, as the last is similarly held by the last holding device, e.g. the last positioning arms, which means that the mould device with the footwear now having the moulded e.g. outer sole or midsole is not necessarily attached to any machinery and may be moved independently of any machinery apart from transport means such as a conveyor. Thus, while curing at 116, the mould device may be e.g. stored at a buffer zone until a predefined curing stage, for example estimated from a temperature measurement of the mould, the last, the moulded sole or any other part. Hereafter the mould device may be opened at 118 and the produced footwear may be retrieved at 120, whereafter it may be subjected to any further processing 122 to gain a desired condition, appearance, etc.

[0146] In connection with steps 118 and 120, the footwear is being removed from the last that has been used in the production of this particular piece of footwear, thus retrieving the last as indicated at 124. This last may as indicated by the dash line be reintroduced in the production, e.g. by allocating it to a production corresponding to the last size and type, applying a footwear upper to it, etc.

[0147] Similarly, the mould device that is retrieved at 126 after having been opened and after the last and the produced footwear has been removed, may be reintroduced in the footwear production, e.g. by cleaning it in the open state that it now is in, possibly by applying anti-stick agents or the like, by closing it and by e.g. keeping it at a specified ambient temperature, cooling or heating it in view of moulding production considerations, etc. before it as indicated may be reintroduced in the production line at 100.

[0148] The flow diagram shown in FIG. 9b corresponds to the one shown in FIG. 9a, but in FIG. 9b it is further illustrated that after closing the mould at 110, the bottom mould is moved upwards at 111. At a point in time the material is injected at 112 and subsequent to this, the bottom is moved further upwards at 111 until it is locked at 114.

[0149] Furthermore, the flow diagram shown in FIG. 9c corresponds to the one shown in FIG. 9a, but in FIG. 9c it is further illustrated that a separate flow of preparation of the bottom mould may be included in the footwear production process. Thus, for example in connection with step 126, where the mould device is retrieved, the bottom mould may be removed at 127 and taken out for a separate flow of preparation, e.g. including a bottom preparation step 128, whereafter the bottom later meets the mould device itself again and is included at 129, for example immediately after the mould device has been prepared at 104 as indicated in FIG. 9c.

[0150] It is noted that the various embodiments as illustrated in FIGS. 9a, 9b and 9c may be combined in any combination and that other variations and/or modifications may be included as well.

[0151] FIG. 10 is a schematic view from above of a direct injection moulding system 130 comprising a plurality of stations 140a-140d, and wherein mould devices, e.g. as shown with the schematic example 2, are transferred from one station to the next during manufacturing. The system comprises a transport system for transferring the mould devices 2, which transport system may comprise various transport devices, e.g. conveyors, carts, etc. At e.g. the location of a plurality of stations 140a-140d, the transport system may comprise a conveyor system essentially comprising for example two carrier beams 132, which are arranged along the length of the production zone that is covered by the stations 140a-140d and at a level below these stations. As indicated by the double-arrow F in FIG. 10, these carrier beams 132, which are also referred to a walking beams, are configured to reciprocate, e.g. at a fixed pattern, meaning that e.g. after a predetermined time or in dependence on a control parameter, the carrier beams 132 are moved forward, i.e. in the production direction E and subsequently moved back again, where they pause. Thus, this pattern is repeated cyclically and may be effected in various manners and by use of various drive arrangements. For example, the drive may be effected by a controlled drive motor having a crank on a drive wheel, where the motor is controlled for each cycle to move the drive wheel one revolution. Another drive arrangement may be a linear drive, e.g. like a servo drive. Other options are possible and will be available, as it will be apparent to a skilled person.

[0152] To further effect the transfer of the mould devices 2, each carrier beam 132 has as indicated a carrier sub-beam 134 at each station, which carrier sub-beams 134 have carrier sub-beam pins 136. The carrier sub-beams 134 and/or the carrier sub-beam pins 136 are arranged such that they are moved upwards during at least part of the movement of the carrier beams 132 in the production direction, whereby the carrier sub-beam pins 136 may engage with corresponding tap holes in the bottom of the side mould device 2, e.g. in the bottom of the side moulds 4, 6. At a point, e.g. when the carrier beams 132 reverse, the carrier sub-beam pins 136 are moved downwards again and will disengage with the respective side mould devices 2, thus meaning that any side mould device 2 that has been at one of the stations, has been transferred a fixed length, corresponding to the distance between two neighbouring stations 140a-140d.

[0153] It is noted that other means than e.g. carrier sub-beam pins 136 and corresponding tap holes may be used for effecting the movement, transfer, etc.

[0154] Further, at the respective stations, further actuators or the like may be arranged, e.g. in order to handle the mould device 2 during opening, positioning of last, closing of side moulds and bottom mould, injection of moulding material, curing, etc.

[0155] Thus, a pair of carrier plates 138 may be arranged such that they will be immediately below a possible mould device at the particular station. Such a pair is illustrated in connection with the station 140c, where the pair of carrier plates 138 are arranged in parallel and may be moved away from each other and towards each other as indicated by the double-arrow. Each carrier plate has a number of e.g. carrier plate pins 139 and the carrier plates 138 and/or the carrier plate pins 139 are arranged such that they may be moved upwards and downwards, where at the upper level they may engage with corresponding tap holes in the bottom of the side mould device 2, e.g. in the bottom of the side moulds 4, 6. Thus, by moving a pair of carrier plates 138 from each other, when the pins engage the side moulds of a mould device 2, the side moulds 4, 6 may be moved away from each other, whereby the mould device is opened. Correspondingly applies, when the pair of carrier plates 138 is moved towards each other, whereby the mould device 2 is closed, e.g. the side moulds are closed.

[0156] Further actuators may be arranged at one or more of the stations, e.g. an actuator for opening or closing of a mould locking device 50, a bottom mould locking tap 54, etc. depending on the functionality that a particular station is intended to have.

[0157] As furthermore shown in FIG. 10, a mould device infeed 146 is arranged to feed the system 130 with empty mould devices 2, of which one is illustrated, seen from above, to the left in FIG. 10. Such a mould device infeed 146 may be a conveyor. When the mould device 2 is fed to the system 130, e.g. to the station 140a, the mould device 2 may be unlocked and the side moulds may be moved away from each other, e.g. by a pair of carrier plates 138 as explained above.

[0158] At the next step performed by the system 130, the mould device 2 will be transferred to the station 140b, where any preparation can be performed in the open state, e.g. inspection, application of anti-stick agents or the like.

[0159] It is noted that in connection with such operations as inspection, cleaning, application of anti-stick agents or the like which preferably takes place in an open state, the side moulds of the mould device may be flipped or tilted, e.g. as it has been illustrated and explained in connection with FIG. 1, whereby e.g. more space is made available for the respective operations, which may be particularly advantageous when the mould device is used in a walking beam or carrier beam system, where distances to neighbouring moulds may be relatively small.

[0160] In the subsequent step, the mould device is transferred to the station 140c, where by means of an automated handler 142, e.g. an industrial robot, a last is introduced to the open mould device 2 and the side moulds 4, 6 are moved towards each other to close the mould device, e.g. by a pair of carrier plates 138 as explained above, whereby the last is held by the last holding device 16. The mould locking device 50 is activated to keep the side moulds locked to each other. Also, the bottom mould may be moved an initial step towards its end position.

[0161] Subsequently, the mould device 2 is transferred to the last station 140d, where mould injection equipment 144 is arranged and may be connected to the injection channel 34 in order to inject moulding material to the mould cavity. The injection step may also include that the bottom mould is moved to its end position by an actuator, where it is locked in place, e.g. by a bottom mould locking tap 54 or by corresponding means.

[0162] At the end of the injection, and after the bottom mould has been locked in its end position, the mould device may now be moved as an independent unit and may be moved to a suitable location for curing, storing, etc. In FIG. 10 it is shown that such a mould device 2 with a piece of footwear, e.g. an upper on a last 20 held by the last holding device 16, to which a sole part, e.g. an outsole, has been moulded, has been transferred to an outfeed 148. Such an outfeed 148 may be a conveyor, a cart, a transport means, etc.

[0163] It is noted that in connection with FIG. 10 four stations have been shown and explained, but fewer or more than four stations may as well be the case, depending on the actual functions that have to be exerted, e.g. in total and/or at each of the stations. The demands may be met by providing carrier beams of various lengths and it will be understood that the system may be applied in a modular fashion as it will be further exemplified in the following.

[0164] Thus, it will be understood that the stations 140a-d that have been illustrated in FIG. 10 may be modules that may be added, removed, exchanged, interchanged, etc., thus for example giving new functions to the already implemented direct injection moulding system or in case of maintenance, etc. Thus, each station may have its separate frame that may be connected, e.g. bolted, to the other stations to form a base frame and similarly, the carrier beams 132 may be configured modularly, e.g. whereby a carrier beam may be shortened, in case a station is removed, by removing a modular length of the carrier beam and correspondingly, a carrier beam may be increased in length, in case a station is added, by adding a modular length of the carrier beam. Thus, a change of the modular station configuration may be effected quickly.

[0165] It is furthermore noted that in the example of FIG. 10, the handling of only one mould device has been explained, but it is clear that a mould device 2 may be present at more stations or at all stations at any time.

[0166] The modularity of the direct injection moulding system 130 will be further illustrated with reference to FIG. 11, which shows a system drawn in a smaller scale and wherein only some of the major parts have been shown. Thus, a mould device infeed 146 with a mould device 2 is shown, ready to be transferred to the direct injection moulding system 130 and where correspondingly an outfeed of mould devices with soled footwear 148 is arranged at the other end of the system 130. The illustrated system 130 comprises two plural stations modules 149a and 149b, but it will be understood that more than two (or one only) may be used to form the system 130. Also, it will be understood that furthermore one or more additional stations, e.g. stations like one or more of the stations 140a-140h may be added to the two plural stations modules 149a and 149b, e.g. in order to achieve a desired functionality.

[0167] By such an arrangement, it may be achieved that a large degree of flexibility is enabled since a plural stations module 149a or 149b that in itself comprises a plurality of stations, e.g. 140a-140d, may be moved as a (working) module that may be e.g. added or removed from a direct injection moulding system. Thus, a double modularity is achieved, since the plural stations module may be combined not only with other plural stations modules, but may additionally be combined with single station modules, e.g. one or more of 140a-140h. Also, it will be understood that e.g. one of the single station modules, e.g. 140a-140h, may be removed as a module from a plural stations module, e.g. 149a or 149b.

[0168] In the above description, various embodiments of the invention have been described with reference to the drawings, but it is apparent for a person skilled within the art that the invention can be carried out in an infinite number of ways, using e.g. the examples disclosed in the description in various combinations, and within a wide range of variations within the scope of the appended claims.

LIST OF REFERENCE NUMBERS

[0169] 2 Mould device [0170] 4 First side mould [0171] 6 Second side mould [0172] 8 Bottom mould [0173] 10 First side surface [0174] 12 Second side surface [0175] 14 Bottom inner surface [0176] 16 Last holding device [0177] 18 Last positioning arm [0178] 20 Last [0179] 22 Last holder [0180] 24 Fixing device [0181] 26 Arm gripper part [0182] 28 Last gripper part [0183] 30 Footwear upper [0184] 32 Lip [0185] 34 Injection channel [0186] 36 Recess [0187] 40 Mould cavity [0188] 50 Mould locking device [0189] 52 Locking tap [0190] 54 Bottom mould locking tap [0191] 56 Last holding device connecting tap [0192] 60 Injected material [0193] 62 Footwear sole [0194] 70 Last holding device base [0195] 72 Base connector [0196] 100 Receiving mould device [0197] 102 Opening mould device [0198] 104 Preparation of mould device [0199] 106 Providing a last [0200] 108 Positioning of last [0201] 110 Closing of mould [0202] 111 Move bottom [0203] 112 Injecting material [0204] 114 Lock bottom mould [0205] 116 Curing [0206] 118 Opening [0207] 120 Providing soled footwear [0208] 122 Further processing [0209] 124 Retrieving last [0210] 126 Retrieving mould device [0211] 127 Bottom removed [0212] 128 Bottom prepared [0213] 129 Bottom included [0214] 130 Direct injection moulding system [0215] 132 Carrier beam [0216] 134 Carrier sub-beam [0217] 136 Carrier sub-beam pin [0218] 138 Carrier plate [0219] 139 Carrier plate pin [0220] 140a-d Stations [0221] 142 Automated handler [0222] 144 Mould injection equipment [0223] 146 Mould device infeed [0224] 148 Outfeed of mould device with soled footwear [0225] 149a, b Plural stations module [0226] A First side mould lateral movement [0227] A First side mould angular movement [0228] B Second side mould lateral movement [0229] B Second side mould angular movement [0230] C Bottom mould vertical movement [0231] D Vertical movement of last [0232] E Production direction [0233] F Reciprocation directions