MOLD FOR FORMING THREE-DIMENSIONAL EMBOSSMENTS ON A SURFACE OF A SHOE PART AND THE MANUFACTURING METHOD THEREOF

Abstract

A method for manufacturing a mold for forming three-dimensional embossments on a surface of a shoe part, comprising: making a high-resolution template with a texture structure; using the high-resolution template to make a high-resolution pattern mold, forming a boundary wall inside the mold through the texture structure; defining, by the boundary wall, different regions provided for being filled with polyurethane compositions of different colors.

Claims

1. A method for manufacturing a mold for forming three-dimensional embossments on a surface of a shoe part, comprising: making a template with a texture structure; filling a casting material into the template to make a mold, and forming a corresponding texture inside the mold through the texture structure.

2. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 1, wherein the corresponding texture is a boundary wall, the boundary wall inside the mold is configured to define different regions.

3. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 1, wherein the texture structure on the template is made by irradiating ultraviolet light through a mold masking element.

4. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 1, wherein the texture structure on the template is made by a direct engraving technique.

5. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 1, wherein the casting material of the mold is a two-component composition of silicones.

6. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 2, wherein the casting material of the mold is a two-component composition of silicones.

7. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 3, wherein the casting material of the mold is a two-component composition of silicones.

8. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 4, wherein the casting material of the mold is a two-component composition of silicones.

9. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 1, wherein the casting material of the mold is polymer with high release properties.

10. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 2, wherein the casting material of the mold is polymer with high release properties.

11. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 3, wherein the casting material of the mold is polymer with high release properties.

12. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 4, wherein the casting material of the mold is polymer with high release properties.

13. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 9 wherein the polymer with high release properties comprising polypropylenes, polyethylenes or polybutylene terephthalates.

14. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 10 wherein the polymer with high release properties comprising polypropylenes, polyethylenes or polybutylene terephthalates.

15. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 11 wherein the polymer with high release properties comprising polypropylenes, polyethylenes or polybutylene terephthalates.

16. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 12 wherein the polymer with high release properties comprising polypropylenes, polyethylenes or polybutylene terephthalates.

17. The method for manufacturing the mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 1, wherein the casting material is filled into the template, then vacuumed to form the mold, and the mold is separated from the template after cooling process, and a corresponding texture is formed at a position where the mold corresponds to the template with the texture structure.

18. A mold for forming three-dimensional embossments on a surface of a shoe part, comprising: a mold body made by a template with a texture structure, the mold body includes at least one corresponding texture defined by the texture structure, the mold body is made by a two-component composition of silicones or polymers with high release properties.

19. The mold for forming three-dimensional embossments on the surface of the shoe part as claimed in claim 9, wherein the corresponding texture is a boundary wall, different regions being defined by each of the boundary walls respectively.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] FIGS. 1-11-3 show a development sequence of a photopolymer plate;

[0034] FIG. 2 is a schematic illustration of transparent and opaque sections of a mold masking element;

[0035] FIG. 3 is a schematic illustration of the production of a template by using the mold masking element;

[0036] FIG. 4 is a schematic illustration of a photopolymers curing process carried out according to the transparent sections of the mold masking element;

[0037] FIG. 5 is a schematic illustration showing texture patterns of the photopolymer plate after curing;

[0038] FIG. 6 is a schematic illustration of the partially cured photopolymer plate after a washing process;

[0039] FIG. 7 is a schematic illustration showing the reduction of textured embossment depths of a photopolymer printing plate caused by thicknesses of black lines and degrees of exposure;

[0040] FIG. 8 is a schematic illustration of procedures of filling a mold material into upper patterns and demolding of a finished mold;

[0041] FIG. 9 is a schematic illustration of boundary walls generated by the black lines of the mask;

[0042] FIG. 10 is a schematic illustration showing the effects generated by the difference between different heights of the two boundary walls and a height of outer walls, and the contact with the polyurethane materials inside and outside of the boundary walls, and the height of the boundary walls will be equal to that of the embossment of the plate after separating the polyurethane materials;

[0043] FIG. 11 is an illustration of an image used for production of a pattern.

DETAILED DESCRIPTION OF THE INVENTION

[0044] The foregoing and other technical contents, features and effects of the present invention will be clearly presented in the following detailed description of the preferred embodiments with reference to the drawings.

Specific Embodiment 1

[0045] FIG. 11 shows an image 34 with a 10% simple circular screen at a resolution of 150 lpi (lines per inch), which comprises four types of textures 35, hollow negative letters 36, six positive letters 37 with each of the letters surrounded by a 0.2 mm white line, and grayscale graphics 38. Among them, the negative objects are imaged on a flexographic printing plate (actual product model: 1.7 mm DuPont Cyrel DSP67) by a laser (actual product model: ESCO CDI Spark 4835).

[0046] A main plate is exposed by an exposure unit of the model DuPont Cyrel 1000 for 20 minutes. A back plate does not need to be exposed. The flexographic printing plate is used as a template for producing a silicone mold after the development processing (processing conditions: photosensitive resin 1000P, processor washed with a solvent). A boundary wall with a width of 0.2 mm and a height of 0.3 mm is produced around the white line. A castable silicone two-component rubber (actual product model: Polytek TinSil 70-60) is mixed and poured onto the flexographic printing plate. A mold is formed after the castable silicone two-component rubber has been cured for approximately 20 hours, and the mold is separated from the flexographic printed plate.

[0047] The letters limited by the boundary walls are filled with various colored liquid two-component polyurethane pigments (actual product model: DuraElast 80) from Evermore Chemical: yellow, orange, red, black, brown and pink. The coloring procedure is accomplished by adding a polyhydric alcohol based paste composition with a component amount of 5% of the pigments. There are several points worth noting, in which the PU composition is uniformly spread outward from the boundary walls. The entire mold is then filled with the same composition colored with a cyan pigment. The procedure for all the filling processes is done by a PU injection molding machine (actual product model: Saip SD1). The mold is mounted on an X-Y stepping axial table (actual product model: SXYxC manufactured by Yamaha Motor Co., Ltd.), and the displacement direction and displacement amount are controlled during the filling process according to the procedure.

[0048] The parameter setting of filling rate is 3 g/sec. The filled mold is heated in an oven at 70 C. for 5 minutes. Then, the polyurethane composition is attached to an object under a pressure of 1 kg/cm2 (the actual product model of the aforementioned object is: polyester mesh HF SD2120P, GME). After 30 minutes, the reticulated cured polyurethane composition is taken out from the mold. The permeability of the polyurethanes provides good adhesion to the mesh. All textures are identical to the textures of the template. A normal thickness of the polyurethane portion is 1.5 mm A negative 10% screen, 150 pins per inch, 50 microns deep. The tip of the pin is 20 microns. Employing a 2 mm detailed texture results in a 1 mm deep embossment. Hollow negative (white parts) 14 pt letters produce negative letters with a depth of 0.5 mm on the polyurethanes.

Specific Embodiment 2

[0049] The differences between the implementation objects described herein and that of the specific embodiment 1 lie in: the white lines surrounding each of the positive letters is 1 mm instead of 0.2 mm. The negative objects are imaged by a laser (actual product model: ESCO CDI Spark 4835) on a flexographic printing plate (actual product model: 1.7 mm DuPont Cyrel DSP67). The exposure of the printing plate is complete in 20 minutes (the actual product model is: DuPont Cyrel 1000 exposure unit), and there is no need for exposing the back plate. The flexographic printing plate is used as a template for the silicone mold production after the development processing (photosensitive resin 1000P and treatment procedure of washing with a solvent). A boundary wall with a width of 1 mm and a height of 0.8 mm is produced by the white line surrounding each of the positive letters.

[0050] A castable silicone two-component rubber (Polytek TinSil 70-60) is mixed and poured onto the flexographic printing plate. A mold is formed after the silicone rubber has been cured for approximately 20 hours, and the mold is separated from the flexographic printed plate.

[0051] The letters limited by the boundary walls are filled with various colored liquid two-component polyurethane pigments (actual product model: DuraElast 80) from Evermore Chemical: yellow, orange, red, black, brown and pink. The coloring procedure is accomplished by adding a polyhydric alcohol paste with a component amount of 5% of the pigments, and the polyurethane composition did not uniformly spread outward from the boundary walls.

[0052] The entire mold is then filled with the same composition colored with a cyan pigment. The procedure of all the filling processes is done by a polyurethane injection molding machine (actual product model: Saip SD1). The mold is mounted on an X-Y stepping axial table (actual product model: SXYxC manufactured by Yamaha Motor Co., Ltd.), and the displacement direction and displacement amount are controlled during the filling process according to the procedure.

[0053] The parameter setting of filling rate is 3 g/sec. The filled mold is heated in an oven at 70 C. for 5 minutes. Then, the polyurethane composition is attached to an object under a pressure of 1 kg/cm2 (the actual product model of the aforementioned object is: polyester mesh HF SD2120P, GME).

[0054] After 30 minutes, the reticulated cured polyurethane composition is taken out from the mold. The permeability of the polyurethanes provides good adhesion to the mesh. All textures are identical to the textures of the template. A normal thickness of the polyurethane portion is 1.5 mm. A negative 10% screen, 150 pins per inch, 50 microns deep. The tip of the pin is 20 microns. Employing a 2 mm detailed texture results in a 1 mm deep embossment. Hollow negative (white parts) 14 pt letters produce negative letters with a depth of 0.5 mm on the polyurethanes.

Specific Embodiment 3

[0055] The differences between the implementation objects described herein and that of the specific embodiment 2 lie in: a screen is produced with a resolution of 22.5 lpi. The negative objects are imaged on a flexographic printing plate (actual product model: MacDermid digital MAF 3.96 mm) by a laser (actual product model: ESCO CDI Spark 4835). The main plate is exposed by an exposure unit of the model DuPont Cyrel 1000, which is complete in 25 minutes, and the exposure of the back plate takes 1 minute.

[0056] The flexographic printing plate is used as a template for producing a silicone mold after the development processing (processing conditions: photosensitive resin 1000P, processor washed with a solvent). A boundary wall with a width of 1 mm and a height of 0.8 mm is produced around the white line. A castable silicone two-component rubber (actual product model: Polytek TinSil 70-60) is mixed and poured onto the flexographic printing plate. A mold is formed after the castable silicone two-component rubber has been cured for approximately 20 hours, and the mold is separated from the flexographic printed plate.

[0057] The letters limited by the boundary walls are filled with various colored liquid two-component polyurethane pigments (actual product model: DuraElast 80) from Evermore Chemical: yellow, orange, red, black, brown and pink. The coloring procedure is accomplished by adding a polyhydric alcohol paste with a component amount of 5% of the pigments.

[0058] The entire mold is then filled with the same composition colored with a cyan pigment. The procedure of all the filling processes is done by a polyurethane injection molding machine (actual product model: Saip SD1). The mold is mounted on an X-Y stepping axial table (actual product model: SXYxC manufactured by Yamaha Motor Co., Ltd.), and moved during the filling process according to the procedure.

[0059] The parameter setting of filling rate is 3 g/sec. The filled mold is heated in an oven at 70 C. for 5 minutes. Then, the polyurethane composition is attached to an object under a pressure of 1 kg/cm2 (the actual product model of the aforementioned object is: polyester mesh HF SD2120P, GME).

[0060] After 30 minutes, the reticulated cured polyurethane composition is taken out from the mold. The permeability of the polyurethanes provides good adhesion to the mesh. All textures are identical to the textures of the template. A normal thickness of the polyurethane portion is 3 mm. A negative 10% screen, 150 pins per inch, and 100 microns deep. The tip of the pin is 20 microns. Employing a 2 mm detailed texture results in a 2 mm deep embossment. Hollow negative (white parts) 14pt letters produce negative letters with a depth of 0.8 mm on the polyurethanes.

Specific Embodiment 4

[0061] Using the mesh plate described in embodiment 2, the mold masking element is imaged on a Fujifilm negative film by a Kodak Flexcel NX System. A metal type letterpress plate (actual product model: Toray WS73HII) is exposed with the film under vacuum. The plate is exposed by an exposure unit of the model DuPont Cyrel 1000 for 2 minutes. The flexographic printing plate is used as a template for the silicone mold production after the development processing (AQF Dantex plus treatment procedure of washing with water). A boundary wall with a width of 1 mm and a height of 0.6 mm is produced by the white line surrounding each of the positive letters.

[0062] A castable silicone two-component rubber (Polytek TinSil 70-60) is mixed and poured onto the flexographic printing plate. A mold is formed after the silicone rubber has been cured for approximately 20 hours, and the mold is separated from the flexographic printed plate.

[0063] The letters limited by the boundary walls are filled with various colored liquid two-component polyurethane pigments (actual product model: DuraElast 80) from Evermore Chemical: yellow, orange, red, black, brown and pink. The coloring procedure is accomplished by adding a polyhydric alcohol paste with a component amount of 5% of the pigments. The entire mold is then filled with the same composition colored with a cyan pigment.

[0064] The procedure of all the filling processes is done by a polyurethane injection molding machine (actual product model: Saip SD1). The mold is mounted on an X-Y stepping axial table (actual product model: SXYxC manufactured by Yamaha Motor Co., Ltd.), and moved during the filling process according to the procedure.

[0065] The parameter setting of filling rate is 3 g/sec. The filled mold is heated in an oven at 70 C. for 5 minutes. Then, the polyurethane composition is attached to an object under a pressure of 1 kg/cm2 (the actual product model of the aforementioned object is: polyester mesh HF SD2120P, GME).

[0066] After 30 minutes, the reticulated cured polyurethane composition is taken out from the mold. The permeability of the polyurethanes provides good adhesion to the mesh resulting in all textures being identical to the textures of the template. A normal thickness of the polyurethane portion is 0.6 mm. Employing a 2 mm detailed texture results in a 0.6 mm deep embossment. Hollow negative (white parts) 14pt letters produce negative letters with a depth of 0.4 mm on the polyurethanes, and the colored positive letters are spaced apart from each other by 1 mm of the cyan polyurethane composition.

Specific Embodiment 5

[0067] Using the mesh plate described in embodiment 2, the mold masking element is imaged on a flexographic printing plate (actual product model: 1.7 mm DuPont Cyrel DSP67) by a laser (actual product model: ESCO CDI Spark 4835). The printing plate is exposed by an exposure unit of the model DuPont Cyrel 1000 for 20 minutes. The back plate does not need to be exposed.

[0068] The flexographic printing plate is used as a template for producing a silicone mold after the development processing (processing conditions: photosensitive resin 1000P, processor washed with a solvent). A boundary wall with a width of 1 mm and a height of 0.8 mm is produced around the white line. Polyethylenes (actual product model: Ipethene 4203 manufactured by Cannel Olefins Ltd.) are heated to 140 C. and poured onto the letterpress plate. The plate with the melted polyethylenes is kept at 150 C. for 10 minutes under vacuum. The plate and polyethylenes are then cooled to room temperature, and the polyethylene mold is separated from the letterpress plate.

[0069] The letters limited by the boundary walls are filled with various colored liquid two-component polyurethane pigments (actual product model: DuraElast 80) from Evermore Chemical: yellow, orange, red, black, brown and pink. The coloring procedure is accomplished by adding a polyhydric alcohol paste with a component amount of 5% of the pigments, and the polyurethane composition did not uniformly spread outward from the boundary walls.

[0070] The entire mold is then filled with the same composition colored with a cyan pigment. The procedure of all the filling processes is done by a polyurethane injection molding machine (actual product model: Saip SD1). The mold is mounted on an X-Y stepping axial table (actual product model: SXYxC manufactured by Yamaha Motor Co., Ltd.), and the displacement direction and displacement amount are controlled during the filling process according to the procedure.

[0071] The parameter setting of filling rate is 3 g/sec. The filled mold is heated in an oven at 70 C. for 5 minutes. Then, the polyurethane composition is attached to an object under a pressure of 1 kg/cm2 (the actual product model of the aforementioned object is: polyester mesh HF SD2120P, GME).

[0072] After 30 minutes, the reticulated cured polyurethane composition is taken out from the mold. The permeability of the polyurethanes provides good adhesion to the mesh. All textures are identical to the textures of the template. A normal thickness of the polyurethane portion is 0.6 mm. A negative 10% screen, 150 pins per inch, 50 microns deep. The tip of the pin is 20 microns. Employing a 2 mm detailed texture results in a 0.6 mm deep embossment. Hollow negative (white parts) 14pt letters produce negative letters with a depth of 0.4 mm on the polyurethanes.

Specific Embodiment 6

[0073] Using the mesh plate described in embodiment 2, the mold masking element is imaged on a Fujifilm negative film by a Kodak Flexcel NX System. A metal type letterpress plate (actual product model: Toray WS73HII) is exposed with the film under vacuum. The plate is exposed by an exposure unit of the model DuPont Cyrel 1000 for 2 minutes. The flexographic printing plate is used as a template for the silicone mold production after the development processing (AQF Dantex plus treatment procedure of washing with water). A boundary wall with a width of 1 mm and a height of 0.6 mm is produced around the white line.

[0074] A castable silicone two-component rubber (Polytek TinSil 70-60) is mixed and poured onto the flexographic printing plate. A mold is formed after the silicone rubber has been cured for approximately 20 hours, and the mold is separated from the flexographic printed plate.

[0075] The letters limited by the boundary walls are filled with various colored liquid two-component polyurethane pigments (actual product model: DuraElast 80) from Evermore Chemical: yellow, orange, red, black, brown and pink. The coloring procedure is accomplished by adding a polyhydric alcohol paste with a component amount of 5% of the pigments. The entire mold is then filled with the same composition colored with a cyan pigment.

[0076] The procedure of all the filling processes is done by a polyurethane injection molding machine (actual product model: Saip SD1). The mold is mounted on an X-Y stepping axial table (actual product model: SXYxC manufactured by Yamaha Motor Co., Ltd.), and moved during the filling process according to the procedure.

[0077] The parameter setting of filling rate is 3 g/sec. The filled mold is heated in an oven at 70 C. for 5 minutes. Then, the polyurethane composition is attached to an object under a pressure of 1 kg/cm2 (the actual product model of the aforementioned object is: polyester mesh HF SD2120P, GME).

[0078] After 30 minutes, the reticulated cured polyurethane composition is taken out from the mold. The permeability of the polyurethanes provides good adhesion to the mesh. All textures are identical to the textures of the template. A normal thickness of the polyurethane portion is 0.6 mm Employing a 2 mm detailed texture results in a 0.6 mm deep embossment. Hollow negative (white parts) 14pt letters produce negative letters with a depth of 0.5 mm on the polyurethanes, and the colored positive letters are spaced apart from each other by 1 mm of the cyan polyurethane composition.

[0079] In summary, the above embodiments and drawings are merely the preferred embodiments of the present invention, and the scope of implementation of the present invention is not limited thereto. In other words, all the equivalent changes and modifications made according to the appended claims shall still fall within the scope covered by the appended claims of the present invention.