Shoe forming method

Abstract

The present invention relates to a product forming method, a product, and a shoe. The product forming method comprises the following steps: (1) placing a film on a bottom mold, and fixing the film between the bottom mold and a middle frame; (2) placing an outer housing material on the film, and suctioning the film, so that the film is internally recessed in the direction of the bottom mold, and then performing first curing molding to obtain a molded outer housing; and (3) placing an inner liner material on the molded outer housing, performing second curing molding to obtain a molded inner liner, and demolding to obtain the product.

Claims

1. A product molding method, comprising the following steps: (1) placing a film on a substrate mold, and fixing the film between the substrate mold and a middle frame; (2) placing an outer husk material on the film, sucking the film to sag in towards the substrate mold, attaching the film to a bottom of the substrate mold, holding for 0-5 min, and performing primary curing molding to obtain a molded outer husk; and (3) placing an inner core material in the molded outer husk, performing secondary curing molding to obtain a molded inner core, and releasing the molded inner core to obtain the product, the outer husk material is placed on the film and then the film is sucked, as the film sags in towards the substrate mold, the outer husk material flows with a deformation of the film, forming an outer husk material layer in a hollow of the film; the outer husk material wraps a side and bottom of the inner core material; wherein the outer husk material has a melt viscosity of 1000-5000 mPa/s at 20-450C.

2. The product molding method according to claim 1, wherein the film is a deformable elastic film.

3. The product molding method according to claim 2, wherein the film is any one of a thermoplastic organic film, a thermosetting organic film or a photocurable organic film.

4. The product molding method according to claim 3, wherein the film is any one of an ethylene-vinyl acetate copolymer film, a silicone-type film, a polyvinyl chloride film, a polyethylene film, a rubber film, a thermoplastic polyurethane film or a thermosetting polyurethane film, or a polypropylene film, or a composite film formed by at least two of them.

5. The product molding method according to claim 1, wherein step (1) further comprises: coating a surface treating agent on a surface of the fixed film.

6. The product molding method according to claim 5, wherein the surface treating agent comprises a film anti-adhesive agent.

7. The product molding method according to claim 6, wherein the surface treating agent comprises any one or a combination of at least two of an aqueous release agent, an oil-based release agent or a silicone oil-based additive.

8. The product molding method according to claim 1, wherein step (1) further comprises: heating the substrate mold to 45-85 C.

9. The product molding method according to claim 1, wherein step (1) further comprises: heating the substrate mold to 45-65 C.

10. The product molding method according to claim 1, wherein in step (2), a method of placing the outer husk material comprises one or a combination of at least two of pouring, extruding, spraying, brushing, blow molding or pressing.

11. The product molding method according to claim 1, wherein in step (3), the secondary curing molding is performed at 45-65 C.

12. The product molding method according to claim 11, wherein in step (3), the secondary curing molding is performed for 2-4 min.

13. The product molding method according to claim 1, wherein the outer husk material comprises any one or a combination of at least two of a thermosetting organic material, a photocurable organic material or a thermoplastic organic material.

14. The product molding method according to claim 1, wherein the outer husk material has a density of 0.8-1.5 g/cm.sup.3.

15. The product molding method according to claim 1, wherein the inner core material comprises any one or a combination of at least two of a thermosetting organic material, a photocurable organic material, a thermoplastic organic material or a rubber-type material.

16. The product molding method according to claim 1, wherein the inner core material has a density of 0.15-0.45 g/cm.sup.3.

17. The product molding method according to claim 1, wherein step (2) further comprises: heating the film to 70-120 C. before sucking the film.

18. The product molding method according to claim 17, wherein in step (2), the film is heated by infrared ray-carbon fiber lampshade irradiation.

19. The product molding method according to claim 1, wherein in step (2), sucking the film at a vacuum degree of 0.05 Mpa to 0.1 Mpa.

20. The product molding method according to claim 1, wherein in step (2), sucking the film is specifically pumping off air between the film and the substrate mold.

21. The product molding method according to claim 20, wherein in step (2), a method of pumping off air between the film and the substrate mold is: connecting at least two air outlets at textured sharp corners of the substrate mold, wherein the air outlets are air communicating connected to a vacuuming system, and then starting the vacuuming system to pump off air between the substrate mold and the film.

22. The product molding method according to claim 1, wherein in step (2), the primary curing molding has a temperature of 45-65 C.

23. The product molding method according to claim 22, wherein in step (2), the primary curing molding has a time of 2-5 min.

24. The product molding method according to claim 1, wherein step (2) specifically comprises: heating the film to 70-120 C., pouring the outer husk material onto the film, sucking the film to attach to the bottom of the substrate mold and holding for 0-5 min, and then performing the primary curing molding at 45-65 C. for 2-5 min to obtain the molded outer husk.

25. The product molding method according to claim 1, wherein step (3) further comprises: closing the substrate mold after pouring the inner core material.

26. The product molding method according to claim 1, wherein step (3) specifically comprises: pouring the inner core material onto the molded outer husk, closing the substrate mold, performing secondary curing molding at 45-65 C. for 2-4 min to obtain the molded inner core, cooling, releasing, and optionally peeling off the film to obtain the product.

27. The product molding method according to claim 1, wherein step (4) is performed after step (3): trimming and arranging the released product, and packaging and storing the product passing inspection.

28. The product molding method according to claim 27, wherein the product molding method comprises the following steps: (1) fixing the film between the substrate mold and the middle frame, and optionally coating a surface treating agent on the surface of the film; (2) heating the film to 70-120 C., pouring the outer husk material onto the film, sucking the film to attach to the bottom of the substrate mold and holding for 0-5 min, and then performing the primary curing molding at 45-65 C. for 2-5 min to obtain the molded outer husk; (3) pouring the inner core material onto the molded outer husk, closing the substrate mold, performing the second curing molding at 45-65 C. for 2-4 min to obtain a molded inner core, cooling, releasing, and optionally peeling the film to obtain the product; and (4) trimming and arranging the released product, and packaging and storing the product passing inspection.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1a is a cross-sectional picture of a product obtained by a product molding method provided in Example 1.1.

(2) FIG. 1b is a cross-sectional diagram of a product obtained by a product molding method provided in Example 1.1.

(3) FIG. 2a is a cross-sectional picture of a product obtained by a product molding method provided in Comparative Example 1.1.

(4) FIG. 2b is a cross-sectional diagram of a product obtained by a product molding method provided in Comparative Example 1.1.

(5) FIG. 3a shows a sole obtained by a molding method of Example 2.1.

(6) FIG. 3b shows a sole obtained by a molding method of Comparative Example 2.1.

DETAILED DESCRIPTION

(7) Embodiments of the present application are described below for a better understanding of the present application. It should be apparent to those skilled in the art that the embodiments are only used for a better understanding of the present application and should not be regarded as a limitation on the present application.

Example 1.1

(8) This example provides a sole molding method, which is specifically as follows: a. a substrate mold was heated to 55 C. and sprayed with a release agent, and a thermoplastic polyurethane film was fixed between the substrate mold and a middle frame, and evenly coated with a treating agent (purchased from Shanghai Momentive Co., Ltd., item No. DC-193); b. the film (purchased from Huafon Thermoplastic Polyurethane Co., Ltd., item No. 3385A) was heated to 90 C. by infrared ray-carbon fiber lampshade irradiation, thermosetting polyurethane (Huafeng New Materials JF-I-600/JF-P-500, with a viscosity of 3200 mPa/s at 40 C.) was poured onto the film, and the film was sucked (with a vacuum degree of 0.05 MPa) to attach to the bottom of the substrate mold, held for 1 min, and then subjected to primary heating molding at 60 C. for 3 min to obtain a molded outer husk; c. foam polyurethane (purchased from Huafeng New Materials, item No. JF-I-6322T/JF-P-6333) was poured onto the outer husk, the substrate mold was closed, secondary heating molding was performed at 50 C. for 3 min to obtain a molded inner core, and the molded inner core was cooled, released and separated from the film to obtain the sole; and d. the released product was trimmed, arranged, and then packaged and stored after passing inspection.

(9) The product obtained by the above molding method is shown in FIG. 1a and FIG. 1b, wherein the outer husk has a density of 1.1 g/cm.sup.3, the inner core has a density of 0.32 g/cm.sup.3, the sole achieves no pore, all-sided wrap, one-piece molding, and no adhesive, an overall density is 0.38, the dense outer husk provides excellent stain resistance, wear resistance and hydrolysis resistance, and the sole passes the 50,000-times flexing resistance test (5 mm) at 25 C. and shows no crease when worn.

Example 1.2

(10) This example provides a bicycle saddle molding method, which is specifically as follows: a. a substrate mold was heated to 55 C. and sprayed with a release agent, and a thermoplastic polyurethane film was fixed between the substrate mold and a middle frame; b. the film (purchased from Huafon Thermoplastic Polyurethane Co., Ltd., item No. 3385A) was heated to 110 C. by infrared ray-carbon fiber lampshade irradiation, thermosetting polyurethane (Huafeng New Materials JF-I-600/JF-P-500, with a viscosity of 2800 mPa/s at 40 C.) was poured onto the film, and the film was sucked (with a vacuum degree of 0.08 MPa) to attach to the bottom of the substrate mold, held for 1 min, and then subjected to primary heating molding at 80 C. for 4 min to obtain an outer-substrate outer husk; c. foam polyurethane (purchased from Huafeng New Materials, item No. JF-I-9818/JF-P-4170) was poured onto the outer husk, the substrate mold was closed, secondary heating molding was performed at 60 C. for 4 min to obtain a middle-substrate inner core, and the middle-substrate inner core was released to obtain the bicycle saddle; and d. the released bicycle saddle was trimmed, arranged, and then packaged and stored after passing inspection.

(11) For the bicycle saddle product obtained by the above molding method, the outer husk has a density of 1.08 g/cm.sup.3, the middle-substrate inner core has a density of 0.35 g/cm.sup.3, the bicycle saddle has a low overall density and is soft and comfortable, the surface has no pore, the dense outer husk provides the product with excellent wear resistance, stain resistance and hydrolysis resistance.

Example 1.3

(12) This example provides a sole molding method, which is specifically as follows: a. a substrate mold was heated to 55 C. and sprayed with a release agent, and an elastic silicone film was fixed between the substrate mold and a middle frame; b. the elastic silicone film (purchased from Hangzhou Bald Advanced Materials Co., Ltd., item No. KRR-200 m) was heated to 90 C. by infrared ray-carbon fiber lampshade irradiation, thermosetting polyurethane (Huafeng New Materials Co., Ltd., JF-I-600/JF-P-500, with a viscosity of 3200 mPa/s at 40 C.) was poured onto the film, and the film was sucked (with a vacuum degree of 0.07 MPa) to attach to the bottom of the substrate mold, held for 1.5 min, and then subjected to primary heating molding at 60 C. for 3 min to obtain a molded outer husk; c. foam polyurethane (purchased from Huafeng New Materials Co., Ltd., item No. JF-I-9818T/JF-P-4170) was poured onto the outer husk, the substrate mold was closed, secondary heating molding was performed at 60 C. for 3.5 min to obtain a molded inner core, and the molded inner core was released and separated from the silicone film to obtain the sole; and d. the released sole was trimmed, arranged, and then packaged and stored after passing inspection.

(13) For the product obtained by the above molding method, the outer husk has a density of 1.2 g/cm.sup.3, the inner core has a density of 0.22 g/cm.sup.3, the sole achieves no pore, one-piece molding, and no adhesive, the dense outer husk and low-density foam layer provide the product with not only low density and wear comfort but also excellent stain resistance, wear resistance and hydrolysis resistance, and the appearance of the product has a bright shining effect.

Example 1.4

(14) This example provides a child seat molding method, which is specifically as follows: a. a substrate mold was heated to 80 C. and sprayed with a release agent, and a film was fixed between the substrate mold and a middle frame; b. the elastic silicone film (purchased from Hangzhou Bald Advanced Materials Co., Ltd., item No. KRR-200 m) was heated to 180 C. by infrared ray-carbon fiber lampshade irradiation, thermosetting polyurethane (purchased from Huafon Thermoplastic Polyurethane Co., Ltd., item No. 1385AC) was extruded and poured onto the film, (with a vacuum degree of 0.1 MPa) and the film was attached to the bottom of the substrate mold and held for 2 min, and the materials were cooled to less than 65 C. to obtain a molded outer husk; c. foam polyurethane (purchased from Huafeng New Materials Co. Ltd., item No. JF-I-9818/JF-P-4107) was poured onto the outer husk, the substrate mold was closed, secondary heating molding was performed at 60 C. for 3 min to obtain a molded inner core, and the molded inner core was released and separated from the film to obtain the child seat; and d. the released product was trimmed, arranged, and then packaged and stored after passing inspection.

(15) For the product obtained by the above molding method, the outer husk has a density of 1.2 g/cm.sup.3, the inner core has a density of 0.28 g/cm.sup.3, the dense outer husk of the seat has more excellent stain resistance, easier cleanable performance and good wear resistance compared with leather; the low-density foam layer provide the product with comfortable experience, and the wear resistance of the outer husk reaches less than or equal to 50 mm.sup.3, which greatly increases the serve life of the seat.

Comparative Example 1.1

(16) This comparative example provides a sole molding method, which is specifically as follows: a. a substrate mold was heated to 50 C. and sprayed with a release agent, and a film was fixed between the substrate mold and a middle frame; b. the film was heated to 100 C. by infrared ray-carbon fiber lampshade irradiation, and the film was sucked (with a vacuum degree of 0.1 MPa) to attach to the bottom of the substrate mold; c. foam polyurethane (purchased from Huafeng New Materials, item No. JF-I-6322T/JF-P-6333) was poured onto the film, the substrate mold was closed, secondary heating molding was performed at 120 C. for 6 min, and the materials were cooled and released to obtain the sole; and d. the released product was trimmed, arranged, and then packaged and stored after passing inspection.

(17) The product obtained by the above molding method is shown in FIG. 2a and FIG. 2b, wherein the foam layer has a density of 0.38 g/cm.sup.3, and the product has pores and shows creases after worn for 2 days.

Example 2.1

(18) This example provides a pore-free sole molding method, which is specifically as follows: a. a substrate mold was heated to 55 C. and sprayed with a release agent, and a thermoplastic polyurethane film (purchased from Huafon Thermoplastic Polyurethane Co., Ltd., item No. 3385A) was fixed between the substrate mold and a middle frame, and evenly coated with a treating agent (purchased from Shanghai Momentive Co., Ltd., item No. DC-193); b. the film was heated to 90 C. by infrared ray-carbon fiber lampshade irradiation, foam polyurethane (Zhejiang Huafeng New Materials Co., Ltd., item No. JF-I-6332T/JF-P-6333) was poured onto the film, and held for 0.5 min to fully cover the film surface, the film was sucked (with a vacuum degree of 0.05 MPa) to attach to the bottom of the substrate mold, the substrate mold was closed, heating molding was performed at 60 C. for 3 min, and the heating-molded sole was taken out to obtain the pore-free sole; and c. the pore-free sole was trimmed, arranged, and then packaged and stored after passing inspection.

(19) The sole obtained by the above molding method is shown in FIG. 3a, and the sole has dense surface and no pore, the surface does not peel, the sole has a density of 0.2 g/cm.sup.3, passes the 50,000-times flexing resistance test (5 mm) at 25 C. and shows no crease when worn.

Example 2.2

(20) This example provides a pore-free sole molding method, which is specifically as follows: a. a substrate mold was heated to 45 C. and sprayed with a release agent, and a thermoplastic polyurethane film (purchased from Huafon Thermoplastic Polyurethane Co., Ltd., item No. 3385A) was fixed between the substrate mold and a middle frame, and evenly coated with a treating agent (purchased from Shanghai Momentive Co., Ltd., item No. DC-193); b. the film was heated to 70 C. by infrared ray-carbon fiber lampshade irradiation, foam polyurethane (purchased from Zhejiang Huafeng New Materials Co., Ltd., item No. JF-I-8920/JF-P-6366) was poured onto the film, and held for 0.2 min to fully cover the film surface, the film was sucked (with a vacuum degree of 0.10 MPa) to attach to the bottom of the substrate mold, the substrate mold was closed, heating molding was performed at 45 C. for 5 min, and the heating-molded sole was taken out and separated from the film to obtain the pore-free sole; and c. the pore-free sole was trimmed, arranged, and then packaged and stored after passing inspection.

(21) The sole obtained by the above molding method has dense surface and no pore, the surface does not peel, the sole has a density of 0.4 g/cm.sup.3, passes the 50,000-times flexing resistance test (5 mm) at 25 C. and shows no crease when worn.

Example 2.3

(22) This example provides a pore-free sole molding method, which is specifically as follows: a. a substrate mold was heated to 65 C. and sprayed with a release agent, and a silicone film (purchased from Hangzhou Bald Advanced Materials Co., Ltd., item No. KNY-500 m) was fixed between the substrate mold and a middle frame; b. foam polyurethane (purchased from Zhejiang Huafeng New Materials Co., Ltd., item No. JF-I-4118/JF-P-4170) was poured onto the film, and held for 1 min to fully cover the film surface, the film was sucked (with a vacuum degree of 0.1 MPa) to attach to the bottom of the substrate mold, the substrate mold was closed, heating molding was performed at 65 C. for 2 min, and the heating-molded sole was taken out and separated from the film to obtain the pore-free sole; and c. the pore-free sole was trimmed, arranged, and then packaged and stored after passing inspection.

(23) The sole obtained by the above molding method has dense surface and no pore, the surface does not peel, the sole has a density of 0.7 g/cm.sup.3, passes the 50,000-times flexing resistance test (5 mm) at 25 C. and shows no crease when worn.

Example 2.4

(24) This example provides a pore-free sole molding method, which is specifically as follows: a. a substrate mold was heated to 55 C. and sprayed with a release agent, and an EVA film (purchased from Shenzhen Huilong Plastic Co., Ltd., item No. B07) was fixed between the substrate mold and a middle frame; b. the film was heated to 90 C. by infrared ray-carbon fiber lampshade irradiation, foam thermosetting polyurethane (purchased from Zhejiang Huafeng New Materials Co., Ltd., JF-I-5818/JF-P-6333) was poured onto the film, and held for 0.5 min to fully cover the film surface, and the film was sucked (with a vacuum degree of 0.05 MPa) to attach to the bottom of the substrate mold, the substrate mold was closed, heating molding was performed at 60 C. for 3 min, and the heating-molded sole was taken out to obtain the pore-free sole; and c. the pore-free sole was trimmed, arranged, and then packaged and stored after passing inspection.

(25) The sole obtained by the above molding method has dense surface and no pore, the surface does not peel, the sole has a density of 0.1 g/cm.sup.3, passes the 50,000-times flexing resistance test (5 mm) at 25 C. and shows no crease when worn.

Example 2.5

(26) This example provides a pore-free sole molding method, which is specifically as follows: a. a substrate mold was heated to 55 C. and sprayed with a release agent, and a thermoplastic polyurethane film (purchased from Huafon Thermoplastic Polyurethane Co., Ltd., item No. 3385A) was fixed between the substrate mold and a middle frame; b. the film was heated to 90 C. by infrared ray-carbon fiber lampshade irradiation, foam EVA (Korea Hyundai Petrochemical Co., Ltd., item No. ES430/ES440) was poured onto the film, and held for 0.5 min to fully cover the film surface, the film was sucked (with a vacuum degree of 0.05 MPa) to attach to the bottom of the substrate mold, the substrate mold was closed, heating molding was performed at 60 C. for 3 min, and the heating-molded sole was taken out and separated from the film to obtain the pore-free sole; and c. the pore-free sole was trimmed, arranged, and then packaged and stored after passing inspection.

(27) The sole obtained by the above molding method has dense surface and no pore, the surface does not peel, the sole has a density of 0.9 g/cm.sup.3, passes the 50,000-times flexing resistance test (5 mm) at 25 C. and shows no crease when worn.

Comparative Example 2.1

(28) This comparative example differs from Example 2.1 only in step (2) that: the film (purchased from Huafon Thermoplastic Polyurethane Co., Ltd., item No. 3385A) was heated to 90 C. by infrared ray-carbon fiber lampshade irradiation, then the film was sucked (with a vacuum degree of 0.05 MPaa) to attach to the bottom of the substrate mold, foam polyurethane (purchased from Zhejiang Huafeng New Materials Co., Ltd., JF-I-6322T/JF-P-6333) was poured onto the film, the substrate mold was closed, heating molding was performed at 60 C. for 3 min, and the heating-molded sole was taken out to obtain the sole.

(29) The product obtained by the molding method of Comparative Example 2.1 is shown in FIG. 3b, there are lots of pores as shown in the picture, and the sole has a density of 0.2 g/cm.sup.3, fails to pass the 50,000-times flexing resistance test (5 mm) at 25 C. and shows creases after worn for 2 days.

Comparative Example 2.2

(30) This comparative example provides a midsole molding method, which is specifically as follows: a. a substrate mold was heated to 55 C. and sprayed with a release agent, and an EVA film was fixed between the substrate mold and a middle frame; b. the film (purchased from Shenzhen Huilong Plastic Co., Ltd., item No. B07) was heated to 90 C. by infrared ray-carbon fiber lampshade irradiation, the film was sucked (with a vacuum degree of 0.05 MPa) to attach to the bottom of the substrate mold, foam thermosetting polyurethane (purchased from Zhejiang Huafeng New Materials Co., Ltd., item No. JF-I-5818/JF-P-6333) was poured onto the film, the substrate mold was closed, heating molding was performed at 60 C. for 3 min, and the heating-molded sole was taken out and separated from the film to obtain the pore-free sole; and c. the pore-free sole was trimmed, arranged, and then packaged and stored after passing inspection.

(31) The sole obtained by the molding method of Comparative Example 2.2 has a density of 0.1 g/cm.sup.3, the surface peels seriously, and the side and bottom surfaces have lots of pores.

Comparative Example 2.3

(32) This comparative example provides a midsole molding method, which is specifically as follows: a. a substrate mold was heated to 55 C. and sprayed with a release agent, a thermoplastic polyurethane film was fixed between the substrate mold and a middle frame, and 60% air between the substrate mold and the film was pumped off to force the film to sag in towards the substrate mold; b. foam polyurethane (Zhejiang Huafeng New Materials Co., Ltd., item No. JF-I-8920/JF-P-6366) was poured into the substrate mold, the substrate mold was closed, and the foam material encased in the film was allowed to foam; during the foaming process, the foam material was wrapped tightly by the film, air between the substrate mold and the film was extruded and expelled out, then the sole wherein the substrate mold, film and foam material were appressed to each other closely is subjected to curing molding at 55 C. for 5 min, and the heating-molded sole was cooled and released to obtain the midsole; and c. the released product was trimmed, arranged, and then packaged and stored after passing inspection.

(33) The product obtained by the above molding method has a density of 0.2 g/cm.sup.3, the side and bottom surfaces have lots of pores, and the bottom texture is blurry because the film encasing the foam material cannot fully attach to the wall of the sole mold.

Comparative Example 2.4

(34) This comparative example provides a midsole molding method, which is specifically as follows: a. a substrate mold was heated to 55 C. and sprayed with a release agent; b. foam polyurethane (purchased from Zhejiang Huafeng New Materials Co., Ltd., item No. JF-I-6322T/JF-P-6333) was poured into the substrate mold, the substrate mold was closed, heating molding was performed at 60 C. for 3 min, and the heating-molded sole was taken out to obtain the midsole; and c. the released product was trimmed, arranged, and then packaged and stored after passing inspection.

(35) The sole obtained by the molding method of Comparative Example 2.4 has a molding density of 0.2 g/cm.sup.3, the surface peels seriously, and the side and bottom surfaces have lots of pores.

(36) The applicant declares that although the embodiments are used in the present application to illustrate the detailed methods of the present application, the present application is not limited to the detailed methods, which means that the present application does not necessarily rely on the detailed methods to be implemented. It should be clear to those skilled in the art that any improvement to the present application, equivalent substitution of each raw material and addition of auxiliary components for the product of the present application, or selection of specific methods, etc., all fall within the protection scope and disclosure scope of the present application.