Method and mold for in-mold integrated molding of polymer foam material and solid sole

Abstract

The invention relates to a method and a mold for in-mold integrated molding of a polymer foam material and a solid sole. Comprising the following steps: providing a pair of dies comprising an upper die holder, a lower die holder, and a first insert and a second insert which are respectively embedded on the upper die holder and the lower die holder; the first insert is provided with a convex block and a first runner arranged in or on the outer surface of the convex block; the second insert is provided with a mold cavity and a second runner arranged in or on the outer surface of the mold cavity; putting a solid wear-resistant shoe sole material and a midsole protection material for manufacturing a high-molecular foaming midsole layer into the mold cavity; the mold is closed, air in the mold cavity is pumped out through vacuumizing, then hot fluid is input into the first flow channel and the second flow channel for heating, and one-time molding shoe sole manufacturing is achieved; and finally, performing cold setting, and taking out the formed sole. The in-mold integrated molding of the polymer foaming material and the solid sole is realized, the defects of inconvenience and high-cost manufacturing of the existing soles made of different materials in actual production are overcome, the time required by the manufacturing process is saved, and the production efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of sole manufacturing, and in particular to a method and a mold for manufacturing a double-layer sole. Background Art

[0002] Traditional sole production methods, in response to different materials and actual molding needs, usually have a variety of production modes. According to the characteristics of the plastic material of the sole, the more common ones are general injection molding or extrusion molding. In accordance with the different colors or material characteristics of the actual sole molding, there will be different process changes such as multi-stage production and then combining. Especially for materials that generally contain foaming materials, due to the changes in their foaming coefficient during production and molding, the entire molding process needs to be produced separately in order to achieve the required fixed stacking. This is especially true for the general sole, commonly known as the outsole, the middle stacked midsole and insole. The shoe sole, etc., usually need to be independently manufactured and formed separately due to the different materials used, and then cut, stacked or glued in sequence to form the structure of the sole. Not only are the processes numerous and complicated, but the overall production cost is also high. In particular, the midsole made of commonly used foam materials needs to be manufactured separately because the foam material and molding properties are completely different from those of the outsole material. Therefore, the foam material needs to be made separately and then appropriately stacked or pressed and glued into shape. In addition, multiple sets of molding molds are required, which are costly, large and heavy, and have poor thermal conductivity, causing many inconveniences in actual production. Therefore, further improvement is needed. Summary of the Invention

[0003] The present invention aims to provide a method and mold for integrally molding a polymer foam material and a solid sole in a mold, which effectively solves the above-mentioned technical problems. By using the same mold, through a molding process of heating and pressurizing, the solid and foam soles can be completely molded. This simplifies and improves the inconvenience and high cost of manufacturing the existing sole structures made of different materials, saves time in the manufacturing process, and improves production efficiency.

[0004] To achieve the above object, the present invention provides a method for integrally forming a polymer foam material and a solid sole in a mold, comprising the following steps: S1. Provide a pair of molds, which include an upper mold base, a lower mold base, a first insert assembled on the upper mold base and capable of replacement, and a second insert assembled on the lower mold base and capable of replacement; the first insert is provided with a protrusion, the protrusion comprising a first outer wall that is convex, a first inner wall that is opposite to the first outer wall and is concave, and a first flow channel, the first flow channel is located between the first outer wall and the first inner wall or attached to the surface of the first inner wall; the first flow channel is connected to the first steam water channel to form a heating circuit system, and the sole is formed by heat conduction through the protrusion; the second insert is provided with a mold cavity, the mold cavity comprising a second outer wall that is convex, a second inner wall that is opposite to the second outer wall and is concave and a second flow channel, which is located between the second outer wall and the second inner wall or attached to the surface of the second outer wall; the second flow channel is connected to the second steam water channel to form a heating circuit system, and the sole is formed by heat conduction through the mold cavity; and the lower mold base is also provided with a vacuum cavity, the second outer wall of the mold cavity protrudes into the vacuum cavity, and a ventilation portion is provided in a part of the mold cavity, and the ventilation portion is connected to the vacuum cavity so that the air in the mold cavity can be extracted through the vacuum cavity; when the upper mold base and the lower mold base are closed, the convex block is correspondingly embedded in the mold cavity and pressed together for heating and pressurizing the sole; the shape of the convex block and the mold cavity matches the shape of the sole to be produced, and corresponding patterns are provided on the second inner wall of the mold cavity; S2. Put the raw materials into the mold, put the solid wear-resistant sole material and the midsole protection material for the polymer foamed midsole into the mold cavity of the second insert, then close the upper mold base and the lower mold base, and fit the protrusions of the first insert into the mold cavity to press the sole material and the midsole protection material together; S3, molding, the air in the mold cavity is extracted through the vacuum chamber, and then hot fluid is input into the first flow channel and the second flow channel for heating and pressurizing molding, so that the sole material and the midsole protective material are naturally combined and molded, and the sole is molded in one step; S4, cooling and opening the mold, inputting cooling liquid into the first runner and the second runner for cold setting, then opening the mold and taking out the formed solid and foamed soles.

[0005] The above scheme is further that, in step S2, the sole material is a solid sole material that is vulcanized once, and the midsole protective material is a polymer prototype foam material made by foaming a polymer foam material. The solid sole material that is vulcanized once and attached with adhesive is placed in the mold cavity, and then the polymer prototype foam material is placed in it. Then, the upper mold base and the lower mold base are closed, and the protrusions of the first insert are correspondingly embedded in the mold cavity and pressed together; and then the subsequent steps are carried out to achieve the production of the sole that is molded once.

[0006] The above scheme is further that, in step S2, the sole material can also be an unvulcanized synthetic rubber sole material, and the midsole protective material is a polymer synthetic material with a foaming material. The unvulcanized synthetic rubber sole material is first placed in the mold cavity, and then the polymer synthetic material with a foaming material is placed. Then, the upper mold base and the lower mold base are closed, and the protrusions of the first insert are correspondingly embedded in the mold cavity and pressed together; and then the subsequent steps are carried out to achieve the production of a sole that is vulcanized and foamed in one step.

[0007] The above solution is further characterized in that, in step S4, the upper die base and the lower die base are cooled and heat is dissipated.

[0008] In order to achieve the above-mentioned purpose, the present invention provides a mold suitable for the integrated molding of polymer foam materials and solid soles, the mold comprising an upper mold base, a lower mold base, a first insert assembled on the upper mold base and capable of replacement, and a second insert assembled on the lower mold base and capable of replacement; the first insert is provided with a convex block, the convex block comprises a first outer wall that convexes outward, a first inner wall that is opposite to the first outer wall and concavely arranged, and a first flow channel, the first flow channel is located between the first outer wall and the first inner wall or attached to the surface of the first inner wall; the first flow channel is connected to the first steam water channel to form a heating circuit system, and the sole is formed by heat conduction through the convex block; the second insert is provided with a mold cavity, the mold cavity comprises a second outer wall that convexes outward, a first inner wall that is opposite to the second outer wall and concavely arranged, and a first flow channel. A second inner wall and a second flow channel are arranged opposite to each other and are concave, and the second flow channel is located between the second outer wall and the second inner wall or attached to the surface of the second outer wall; the second flow channel is connected with the second steam water channel to form a heating circuit system, and the sole is formed by heat conduction through the mold cavity; and a vacuum cavity is also provided on the lower mold base, the second outer wall of the mold cavity protrudes into the vacuum cavity, and a breathable portion is provided on a part of the mold cavity, and the breathable portion is connected with the vacuum cavity so that the air in the mold cavity can be extracted through the vacuum cavity; when the upper mold base and the lower mold base are closed, the protrusions are correspondingly embedded in the mold cavity and pressed together for heating and pressurizing the sole; the shapes of the protrusions and the mold cavity match the shape of the sole to be produced, and corresponding patterns are provided on the second inner wall of the mold cavity.

[0009] The above solution is further that the first insert and the second insert are printed by 3D metal printing technology, the shapes of the protrusion and the mold cavity match the shape of the sole to be produced, the first runner is printed according to the shape of the protrusion, and the second runner is printed according to the shape of the mold cavity; the interior of the upper mold base is also provided with a first cooling runner, and the peripheral wall of the lower mold base is also provided with a second cooling runner, and the first cooling runner and the second cooling runner are used to introduce coolant to dissipate heat to the upper mold base and the lower mold base respectively.

[0010] The above solution is further characterized in that the first insert is inserted into a first assembly groove preset on the upper die base, the first insert further has a first overlapping edge extending outward from the periphery of the protrusion, the notch of the first assembly groove is provided with a first receiving groove extending outward, and when the first insert is inserted into the first assembly groove, the first overlapping edge is embedded in the first receiving groove and is locked with screws; The first flow channel is connected to the first steam water channel at the junction of the first overlapping edge and the first receiving groove, and the first steam water channel extends to the upper mold base; or the first flow channel is connected to the first steam water channel outside the upper mold base, and the first flow channel extends from the upper mold base through the first extension joint or the additional first external tube constructed by the local extension printing of the first overlapping edge, and the upper mold base is provided with a first recessed portion for matching the first extension joint or the first external tube; the outer end of the first extension joint or the first external tube is directly connected to the first steam water channel.

[0011] The above solution further comprises the following features: the second insert is embedded in a second assembly groove preset on the lower mold base, the second assembly groove being an inner groove with an upward opening; the air permeable portion on the second insert is constructed of air permeable steel embedded during 3D printing, and the second insert and the peripheral wall of the second assembly groove enclose a vacuum chamber; the second insert also has a second overlapping edge extending outward from the periphery of the mold cavity, and the notch of the second assembly groove is provided with a second receiving groove extending outward. When the second insert is embedded in the second assembly groove, the second overlapping edge is embedded in the second receiving groove and is locked with screws; The second flow channel is connected to the second steam water channel at the junction of the second overlapping edge and the second receiving groove, and the second steam water channel extends to the lower mold base; or the second flow channel is connected to the second steam water channel outside the lower mold base, and the second flow channel extends from the lower mold base through a second extension joint or an additional second external tube constructed by local extension printing of the second overlapping edge, and the lower mold base is provided with a second recessed portion that matches the second extension joint or the second external tube; the outer end of the second extension joint or the second external tube is directly connected to the second steam water channel.

[0012] The above solution is further that the lower mold base is composed of a middle frame and a back plate, one end of the middle frame is against and locked on the back plate, and the inner hollow part of the middle frame forms a second assembly groove; a vacuum hole connected to the vacuum chamber is opened on the back plate.

[0013] The above solution is further characterized in that the diameter of the ventilation holes of the ventilation portion is between 50um and 200um; and the ventilation portion and the second flow channel are arranged in a staggered manner so as not to interfere with each other.

[0014] By adopting the above technical means, the present invention has the following effects: 1. Using the same mold, different sole materials are filled in batches at once. Through a single pressing and shaping process, the two-layer sole is formed into a single piece. No overlapping or bonding steps are required, reducing the manual application of glue or treatment agents during the sole assembly process, saving labor, reducing costs and increasing efficiency. At the same time, it ensures the simplification of sole production and the consistency and stability of product quality, effectively improving product quality and reducing production costs. It simplifies and improves the inconvenience and high cost of existing sole structures made of different materials in actual production, truly meeting the purpose of industrial practical value.

[0015] 2. Through the vacuum action, the air in the mold cavity is extracted, which improves the tightness and heat transfer between different materials, helps the sole material and the midsole protection material to be naturally combined and tightly combined, so as to achieve the production of the sole molded in one time.

[0016] 3. The mold is designed with a structure that can be quickly changed to achieve standardization of the upper mold base and the lower mold base, while the first insert and the second insert are interchangeable. By quickly replacing the corresponding inserts as needed, different types of protrusions and mold cavities can be obtained for the production of different types of soles, reducing production costs, improving resource utilization, and optimizing the production process.

[0017] 4. Optimize the structure of the inserts and design the structure of the bumps and the mold cavity to reduce the heating volume, making it easier for heat energy to be transferred to the bumps and the mold cavity. The mold cavity is heated quickly and evenly, which is suitable for the one-time molding of solid and foamed soles, and helps to improve the molding speed and quality of the soles, shorten the molding time, and improve production efficiency. At the same time, cooling water can be introduced into the runner space for cooling process, reducing the mold transfer time.

[0018] 5. The first insert is assembled on the upper mold base and connected to the first steam water channel, so that the first flow channel of the first insert can be introduced with hot fluid or coolant as needed; the second insert is assembled on the lower mold base and connected to the second steam water channel, so that the second flow channel of the second insert can be introduced with hot fluid or coolant as needed; the first and second inserts can be independently controlled to introduce hot fluid or coolant, which is convenient for control and is conducive to heating molding and cooling mold opening; and cooling flow channels are added to the upper mold base and the lower mold base to introduce coolant to dissipate heat to the upper and lower mold bases, effectively preventing secondary heating of the finished product caused by the residual heat of the upper and lower mold bases, thereby ensuring the quality of the finished product. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Attachment Figure 1 is a flow chart of the present invention; Attachment Figure 2 This is a schematic cross-sectional view of a preferred embodiment of the mold of the present invention; Attachment Figure 3 for Figure 2 Schematic diagram of the mold opening structure of the embodiment; Attachment Figure 4 for Figure 2 Schematic diagram of the combined form of the first insert and the upper die base of the embodiment; Attachment Figure 5 for Figure 4 Schematic diagram of the assembled first flow channel extending through the attached first external tube; Attachment Figure 6 for Figure 2 Schematic diagram of the combined form of the second insert and the lower die base of the embodiment; Attachment Figure 7 Schematic diagram of a preferred embodiment of the present invention in which the first flow channel and the second flow channel are constructed through an internal interlayer; Attachment Figure 8 A schematic diagram of an embodiment of the present invention in which the second flow channel is attached to the surface of the second outer wall; Attachment Figure 9 This is a schematic diagram of an embodiment of the present invention in which the first flow channel and the second flow channel are connected to the first and second steam water channels respectively; Attachment Figure 10 for Figure 9 Schematic diagram of the upper end structure. DETAILED DESCRIPTION

[0020] The concept, specific structure and technical effects of the present invention will be further described below in conjunction with the accompanying drawings to fully understand the purpose, characteristics and effects of the present invention.

[0021] It should be noted that in the description of the present invention, terms such as "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings. These are merely for ease of description and do not indicate or imply that the device or element described must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0022] See Figures 1 to 10 FIG. 1 is a schematic diagram of a preferred embodiment of the present invention. The present invention relates to a method for integrally forming a polymer foam material and a solid sole in a mold, which comprises the following steps: S1. Provide a mold comprising an upper mold base 1, a lower mold base 2, a first insert 3 assembled and replaceable on the upper mold base 1, and a second insert 4 assembled and replaceable on the lower mold base 2. The upper mold base 1 and the lower mold base 2 are mounted on a molding machine and are adapted to move relative to each other to form the sole. The upper mold base 1 and the lower mold base 2, the first insert 3, and the second insert 4 are preferably made of metal, and are preferably fabricated using 3D printing technology to provide good thermal conductivity. The first insert 3 is provided with a protrusion 32, which includes a first outer wall 321 that is convex, a first inner wall 322 that is opposite to the first outer wall 321 and is concave, and a first flow channel 323. The first flow channel 323 is located between the first outer wall 321 and the first inner wall 322 or attached to the surface of the first inner wall 322. The first flow channel 323 is connected to the first steam water channel 11 preset on the upper mold base 1; thus, the first steam water channel 11 can be used to control the entry of hot fluid or coolant into the first flow channel 323, forming a heating system for the heated molding of the sole. When hot fluid is introduced into the first flow channel 323, heating molding is performed, while when coolant is introduced into the first flow channel 323, cooling, shaping and demolding are performed. The hot fluid and coolant are alternately introduced by a control valve, effectively shortening the process time. The second insert 4 is provided with a mold cavity 42, which includes a convex second outer wall 421, a concave second inner wall 422 opposite to the second outer wall, and a second flow channel 423. The second flow channel 423 is located between the second outer wall 421 and the second inner wall 422 or attached to the surface of the second outer wall 421. The second flow channel 423 is connected to the second steam water channel 21 pre-set on the lower mold base 2. Therefore, the second steam water channel 21 can control the entry of hot fluid or coolant into the second flow channel 423. When hot fluid is introduced into the second steam water channel 21, heating and molding are performed, while when coolant is introduced into the second steam water channel 21, cooling and demolding are performed. Similarly, the hot fluid and coolant are alternately introduced by a control valve, effectively shortening the process time. The lower mold base 2 is also provided with a vacuum chamber 22. The second outer wall 421 of the mold cavity 42 protrudes into the vacuum chamber 22. A ventilation portion 424 is provided in a part of the mold cavity 42. The ventilation portion 424 is connected to the vacuum chamber 22 so that the air in the mold cavity 42 can be extracted through the vacuum chamber 22. When the upper mold base 1 and the lower mold base 2 are closed, the protrusion 32 is correspondingly embedded in the mold cavity 42 and pressed together for sole molding. The shapes of the protrusion 32 and the mold cavity 42 match the shape of the sole to be produced. The first flow channel 323 is designed according to the shape of the protrusion 32, and the second flow channel 423 is designed according to the shape of the mold cavity 42 to improve heating uniformity. Different soles can be produced by replacing the first insert 3 and the second insert 4. Corresponding textures are provided on the second inner wall 422 of the mold cavity 42. The textures are distributed on the inner bottom and the surrounding wall of the mold cavity 42, so that corresponding concave and convex textures are pressed on the sole.The mold structure makes the first insert 3 and the second insert 4 thinner and lighter, which facilitates disassembly and heat conduction, reduces energy waste, and improves the production efficiency and quality of the sole.

[0023] S2. Put the raw materials into the mold. Place the solid wear-resistant sole material and the midsole protection material for the polymer foamed midsole layer into the mold cavity 42 of the second insert 4. Then, close the upper mold base 1 and the lower mold base 2. The protrusions 32 of the first insert 3 are correspondingly inserted into the mold cavity 42 to press the sole material and the midsole protection material together. S3, molding, the air in the mold cavity 42 is extracted through the vacuum chamber 22, and then hot fluid is input into the first flow channel 323 and the second flow channel 423 for heating and pressurizing molding, so that the sole material and the midsole protective material are naturally combined and molded, so as to achieve the sole production of the molded sole in one step; S4, cooling and opening the mold, inputting cooling liquid into the first flow channel 323 and the second flow channel 423 for cold setting, then opening the mold and taking out the formed solid and foamed soles.

[0024] In this embodiment, the sole material in step S2 can be a solid sole material that is vulcanized once, such as a rubber-plastic material, and the midsole protective material is a foamed polymer prototype foam material, such as EVA particles that are foamed once to form a prototype. Then, the solid sole material that is vulcanized once and attached with adhesive is placed in the mold cavity 42, and then the polymer prototype foam material is placed in it. Then, the upper mold base 1 and the lower mold base 2 are molded together, and the protrusion 32 of the first insert 3 is correspondingly embedded in the mold cavity 42 and pressed together. Then, the subsequent steps are performed to achieve the single-molding sole production. Among them, the solid sole material that is vulcanized once and attached with adhesive is formed by coating a layer of adhesive film during in-mold vulcanization molding of a synthetic rubber material. The adhesive film is a thin film material composed of an adhesive and a base material. After vulcanization molding, the adhesive film is attached to the solid sole material, and then the release die on the outer surface of the adhesive film is torn off, that is, the sole material is covered with adhesive, which reduces the need for subsequent glue application. The solid sole material that has been vulcanized once and the polymer prototype foam material are heated and pressurized in the mold to form a sole with both a foam protective layer and a solid wear-resistant layer. The adhesive film increases the adhesion, making the two materials more firmly bonded. There is no need for manual bonding process, and they can be directly placed in the mold for bonding, saving labor, reducing costs and increasing efficiency.

[0025] In this embodiment, in step S2, the sole material can also be an unvulcanized synthetic rubber sole material, and the midsole protective material is a polymer synthetic material with a foaming material. The unvulcanized synthetic rubber sole material is first placed in the mold cavity 42, and then the polymer synthetic material with a foaming material is placed. Then, the upper mold base 1 and the lower mold base 2 are molded together, and the protrusion 32 of the first insert 3 is correspondingly embedded in the mold cavity 42 and pressed together; and then the subsequent steps are carried out to achieve the production of a sole formed by one-time vulcanization and foaming molding.

[0026] In step S4, the upper mold base 1 and lower mold base 2 are also cooled to effectively prevent residual heat from the upper and lower mold bases from reheating the finished product, thereby ensuring the quality of the finished product. Step S4 can also be combined with simple trimming to remove the overflowing material, thus forming a complete dual-material sole product.

[0027] See Figures 2 to 10 As shown, the mold provided by the present invention is suitable for the integrated molding of polymer foam materials and solid soles, which includes an upper mold base 1, a lower mold base 2, a first insert 3 assembled on the upper mold base 1, and a second insert 4 assembled on the lower mold base 2; during implementation, the upper mold base 1 and the lower mold base 2 are installed on a molding machine, and the relative movement of the upper mold base 1 and the lower mold base 2 is realized to realize the sole molding process.

[0028] The first insert 3 is provided with a protrusion 32, which includes a first outer wall 321 that is convex, a first inner wall 322 that is concave and opposite to the first outer wall 321, and a first flow channel 323. The first flow channel 323 is located between the first outer wall 321 and the first inner wall 322 or attached to the surface of the first inner wall 322 and is used to introduce hot fluid or coolant. The first flow channel 323 is connected to the first steam water channel 11 to form a heat conduction circuit system, thereby controlling the entry of hot fluid or coolant into the first flow channel 323 through the first steam water channel 11 for sole molding. When hot fluid is introduced into the first flow channel 323, heating and molding are performed, while when coolant is introduced into the first flow channel 323, cooling and demolding are performed.

[0029] The second insert 4 is provided with a mold cavity 42, which includes a convex second outer wall 421, a concave second inner wall 422 opposite to the second outer wall, and a second flow channel 423. The second flow channel 423 is located between the second outer wall 421 and the second inner wall 422 or attached to the surface of the second outer wall 421. The second flow channel 423 is connected to the second steam water channel 21 to form a heat conduction circuit system, thereby controlling the entry of hot fluid or coolant into the second flow channel 423 through the second steam water channel 21 for sole molding. Similarly, when hot fluid is introduced into the second steam water channel 21, heating and molding are performed, and when coolant is introduced into the second steam water channel 21, cooling and demolding are performed.

[0030] This embodiment effectively reduces the volume of the bumps 32 and the mold cavity 42, making the heating volume small, and heat energy is more easily transferred to the bumps and the mold cavity. The mold cavity is heated quickly and evenly, which helps to improve the speed and quality of sole molding, save the time required for the process, improve production efficiency, reduce heat loss, and reduce the cost of use. In this embodiment, the number and position of the bumps 32 correspond to the mold cavity 42. When the upper mold base 1 and the lower mold base 2 are closed, the bumps 32 are correspondingly embedded in the mold cavity 42 and pressed together for sole molding. The design of the first flow channel 323 and the second flow channel 423 not only allows the introduction of hot fluid (hot water, hot oil or steam, etc.) to heat the bumps 32 and the mold cavity 42 for sole molding, but also allows the use of cooling water in the flow channel space for cooling process to facilitate demolding and reduce mold transportation time.

[0031] In this embodiment, the lower mold base 2 is further provided with a vacuum chamber 22. The second outer wall 421 of the mold cavity 42 protrudes into the vacuum chamber 22. The mold cavity 42 is also provided with a vent 424, which communicates with the vacuum chamber 22 to allow air in the mold cavity 42 to be extracted through the vacuum chamber 22. During operation, the vacuum chamber 22 is evacuated by a vacuum pump (not shown). The vacuum chamber 22 is connected to the vacuum pump via air holes provided in corresponding locations on the lower mold base 2 to achieve evacuation. The vent 424 also evacuates the air in the mold cavity 42, facilitating the stretching and molding of the sole material and improving molding quality.

[0032] In this embodiment, the upper die base 1 is further provided with a first cooling channel 13. This channel is used to introduce coolant to dissipate heat from the upper die base 1, providing circulation cooling. This prevents residual heat from the upper die base 1 from being transferred back to the first insert 3, effectively reducing the impact of this residual heat on demolding and subsequent material discharge. Similarly, the peripheral wall of the lower die base 2 is further provided with a second cooling channel 26. This channel is used to introduce coolant to dissipate heat from the lower die base 2, providing circulation cooling. This prevents residual heat from being transferred back to the second insert 4, effectively reducing the impact of this residual heat on demolding and subsequent material discharge.

[0033] In this embodiment, the first insert 3 and the second insert 4 are printed by 3D metal printing technology. The shapes of the protrusion 32 and the mold cavity 42 match the shape of the sole to be produced. The first flow channel 323 is printed according to the shape of the protrusion, and the second flow channel 423 is printed according to the shape of the mold cavity, so as to achieve uniform heat conduction effect.

[0034] The first insert 3 is embedded in the first assembly groove 12 preset on the upper mold base 1. The first insert 3 also has a first lap edge 31 that expands outward from the four sides of the protrusion 32. The notch of the first assembly groove 12 is provided with a first receiving groove 121 that expands outward. When the first insert is embedded in the first assembly groove, the first lap edge is embedded in the first receiving groove and is locked with screws to facilitate disassembly and assembly. The first flow channel 323 is connected to the first steam water channel 11 at the junction of the first lap edge and the first receiving groove. In this case, the first steam water channel 11 extends to the upper mold base 1; or the first flow channel 323 is connected to the first steam water channel 11 outside the upper mold base 1. In this case, the first flow channel 323 extends from the upper mold base 1 through a first extension joint constructed by local extension printing of the first lap edge 31 or an additional first external pipe. Figure 4 、 5 In the embodiments shown in 9 and 10, the first flow channel 323 extends through an additional first external tube 3231 and connects directly to the first steam waterway 11 via a threaded connection, facilitating assembly and disassembly while ensuring a good seal. In this embodiment, the upper mold base 1 is provided with a first recess 14 that mates with the first external tube, facilitating alignment and assembly. Two first external tubes are paired, one for inlet and one for outlet, connecting to the first steam waterway 11 to form a circuit.

[0035] The second insert 4 is embedded in the second assembly groove 23 preset on the lower mold base 2, and the second assembly groove 23 is an inner groove with an opening facing upward; the breathable portion 424 on the second insert 4 is constructed by breathable steel embedded during 3D printing, and the breathable portion 424 and the second flow channel 423 are staggered and arranged without interfering with each other, thereby achieving the integrity of the second insert 4 and water vapor separation, and utilizing the porous steel characteristics of the breathable steel to avoid hole processing. Figure 3 The air permeable portion 424 shown is marked with a local point, but it is not limited to this location and can also be set in other directions, as long as it is connected to the vacuum chamber 22 for vacuuming. The air permeable portion 424 can be designed in the form of a point, line or surface, and can be arranged in multiple points, lines, surfaces or a combination thereof according to the need for vacuuming, as long as it meets the requirements of vacuuming. In this embodiment, the lower mold base 2 is constructed by combining a middle frame 24 and a back plate 25. One end of the middle frame 24 rests on the back plate 25 and is locked, such as by screw locking, and a corresponding sealing ring is added. The inner hollow portion of the middle frame 24 forms a second assembly groove 23. After the second insert 4 is assembled to the lower mold base 2, it also encloses the peripheral wall of the second assembly groove 23 to form a vacuum chamber 22, with good integrity, compact structure and reasonable structure. A vacuum hole 251 is opened on the back plate 25 to connect to the vacuum chamber 22, which is convenient for production and installation. The breathable portion 424 is breathable steel, and the diameter of the breathable holes on the breathable steel is between 50um and 200um. The porous structure of the breathable steel is utilized to meet the strength of the molding structure, while also being able to effectively exhaust air, allowing different materials to be more tightly combined during molding.

[0036] The second insert 4 also has a second lap edge 41 that expands outward from the four sides of the mold cavity 42. The notch of the second assembly groove 23 is provided with a second receiving groove 231 that expands outward. When the second insert 4 is inserted into the second assembly groove, the second lap edge 41 is embedded in the second receiving groove 231 and is locked with screws. A corresponding sealing ring is added. The structure is simple and convenient for disassembly and replacement. The second flow channel 423 is connected to the second steam waterway 21 at the junction of the second lap edge and the second receiving groove. In this case, the second steam waterway 21 extends to the lower mold base 2; or the second flow channel 423 is connected to the second steam waterway 21 outside the lower mold base 2. In this case, the second flow channel 423 extends from the lower mold base 2 through a second extension joint or an additional second external tube constructed by partial extension printing of the second lap edge 41. The lower mold base 2 is provided with a second recessed portion 27 that matches the second extension joint or second external tube. The outer end of the second extension joint or second external tube is directly connected to the second steam waterway 21. Figure 6 、 9 As shown in Figures 10 and 11, the second flow channel 423 extends from the lower mold base 2 via an additional second external tube 4231 and connects directly to the second steam waterway 21 via a threaded connection, facilitating assembly and disassembly while ensuring a good seal. Two second external tubes 4231 are paired, one for inlet and one for outlet, connecting to the first steam waterway 11 to form a loop.

[0037] In this embodiment, Figure 7 As shown, the first flow channel 323 and the second flow channel 423 can be a sandwich structure, which is printed and manufactured as a whole with the first insert and the second insert respectively; wherein, the first flow channel 323 is located between the first inner wall and the first outer wall, and there are corresponding supporting ribs between the first inner wall and the first outer wall; the second flow channel 423 is located between the second inner wall and the second outer wall, and there are corresponding supporting ribs between the second inner wall and the second outer wall, and the air permeable portion 424 on the second insert 4 is just embedded in the corresponding supporting ribs, and is staggered with the second flow channel 423 to ensure water vapor separation. Of course, it can also be as Figure 8 As shown, the second flow channel 423 can also be a pipe structure attached to the corresponding side surface, in the shape of a raised spine, which can be printed integrally with the second insert or printed separately and then assembled to the second insert; the air permeable portion 424 is located between adjacent spines and is formed by 3D printing. The structure is stable and reliable, and it is conducive to making the protrusion 32 and the mold cavity 42 into a light and thin shape. As for the first flow channel, of course, as Figure 8 The structural design shown will not be further described in detail here.

[0038] Figure 9 、 10As shown, on the same side of the mold, the first flow channel 323 is connected to the first steam water channel 11, the second flow channel 423 is connected to the second steam water channel 21, and the first cooling flow channel 13 of the upper mold base 1 is connected to the coolant, and the second cooling flow channel 26 of the lower mold base 2 is connected to the coolant, which is convenient for installation and maintenance.

[0039] The first flow channel 323 and the second flow channel 423 are not limited to the above-mentioned shape design. Grid-shaped flow directions, U-shaped flow directions, etc. can also be designed according to actual conditions. The cross-sectional shapes of the first flow channel and the second flow channel can be designed to be circular, elliptical, teardrop-shaped, polygonal or a combination thereof according to actual conditions. While ensuring the structural strength of the insert, better thermal conductivity can be obtained, thereby improving the molding speed and quality.

[0040] Through experiments, it is known that the present invention can achieve the following effects by adopting the above technical means: 1. Using the same mold, different sole materials are filled in batches at once. Through a single pressing and shaping process, the two-layer sole is formed into a single piece. No overlapping or bonding steps are required, reducing the manual application of glue or treatment agents during the sole assembly process, saving labor, reducing costs and increasing efficiency. At the same time, it ensures the simplification of sole production and the consistency and stability of product quality, effectively improving product quality and reducing production costs. It simplifies and improves the inconvenience and high cost of existing sole structures made of different materials in actual production, truly meeting the purpose of industrial practical value.

[0041] 2. Through the vacuum action, the air in the mold cavity is extracted, which improves the tightness and heat transfer between different materials, helps the sole material and the midsole protection material to be naturally combined and tightly combined, so as to achieve the production of the sole molded in one time.

[0042] 3. The mold is designed with a structure that can be quickly changed to achieve standardization of the upper mold base and the lower mold base, and the first insert and the second insert are interchangeable. By replacing the corresponding inserts as needed, different types of protrusions and mold cavities can be obtained for the production of different types of soles, reducing production costs, improving resource utilization, and optimizing the production process.

[0043] 4. Optimize the structure of the inserts and design the structure of the bumps and the mold cavity to reduce the heating volume, making it easier for heat energy to be transferred to the bumps and the mold cavity. The mold cavity is heated quickly and evenly, which is suitable for the one-time molding of solid and foamed soles, and helps to improve the molding speed and quality of the soles, shorten the molding time, and improve production efficiency. At the same time, cooling water can be introduced into the runner space for cooling process, reducing the mold transfer time.

[0044] 5. The first insert is assembled on the upper mold base and connected to the first steam water channel, so that the first flow channel of the first insert can be introduced with hot fluid or coolant as needed; the second insert is assembled on the lower mold base and connected to the second steam water channel, so that the second flow channel of the second insert can be introduced with hot fluid or coolant as needed; the first and second inserts can be independently controlled to introduce hot fluid or coolant, which is convenient for control and is conducive to heating molding and cooling mold opening; and cooling flow channels are added to the upper mold base and the lower mold base to introduce coolant to dissipate heat to the upper and lower mold bases, effectively preventing secondary heating of the finished product caused by the residual heat of the upper and lower mold bases, thereby ensuring the quality of the finished product.

[0045] 6. The mold has a simple structure and few parts, and the overall shape is light, easy to manufacture and implement.

[0046] Of course, the above detailed description of the present invention in combination with the implementation methods is only for illustrating the technical concept and features of the present invention, and its purpose is to enable people familiar with this technology to understand the content of the present invention and implement it. Therefore, all equivalent changes or modifications made according to the spirit of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for integrally forming a polymer foam material and a solid sole in a mold, characterized in that: The following steps are involved: S1. Provide a mold, the mold comprising an upper mold base (1), a lower mold base (2), a first insert (3) assembled on the upper mold base (1) and capable of replacement, and a second insert (4) assembled on the lower mold base (2) and capable of replacement; the first insert (3) is provided with a protrusion (32), the protrusion (32) comprising a first outer wall (321) that is convex, a first inner wall (322) that is opposite to the first outer wall (321) and is concave, and a first flow channel (323), the first flow channel ( 323) is located between the first outer wall (321) and the first inner wall (322) or attached to the surface of the first inner wall (322); the first flow channel (323) is connected to the first steam water channel (11) to form a heating circuit system, and the sole is formed by heat conduction through the convex block (32); the second insert (4) is provided with a mold cavity (42), and the mold cavity (42) includes a second outer wall (421) that is convex, a second inner wall (422) that is opposite to the second outer wall and is concave, and a second flow channel (423), the second flow channel (423) is located between the second outer wall (421) and the second inner wall (422) or attached to the surface of the second outer wall (421); the second flow channel (423) is connected to the second steam water channel (21) to form a heating circuit system, and the sole is formed by heat conduction through the mold cavity (42); and the lower mold base (2) is also provided with a vacuum cavity (22), and the second outer wall (421) of the mold cavity (42) protrudes into the vacuum cavity (22) and is formed in the mold cavity (42). A ventilation portion (424) is provided locally, and the ventilation portion (424) is communicated with the vacuum cavity (22) so that air in the mold cavity (42) can be extracted through the vacuum cavity (22); when the upper mold base (1) and the lower mold base (2) are closed, the protrusion (32) is correspondingly embedded in the mold cavity (42) and pressed together for heating and pressurizing the sole; the shape of the protrusion (32) and the mold cavity (42) matches the shape of the sole to be produced, and corresponding patterns are provided on the second inner wall (422) of the mold cavity (42); S2, the raw materials are put into the mold, the solid wear-resistant sole material and the midsole protection material for the polymer foamed bottom layer are placed into the mold cavity (42) of the second insert (4), and then the upper mold base (1) and the lower mold base (2) are closed, and the protrusions (32) of the first insert (3) are correspondingly embedded in the mold cavity (42) to press the sole material and the midsole protection material together; S3, molding, extracting the air in the mold cavity (42) through the vacuum chamber (22), and then inputting hot fluid into the first flow channel (323) and the second flow channel (423) for heating and pressurizing molding, so as to achieve natural combination and molding of the sole material and the midsole protective material, thereby achieving one-step molding of the sole; S4, cooling and opening the mold, inputting cooling liquid into the first flow channel (323) and the second flow channel (423) for cold setting, and then opening the mold and taking out the formed solid and foamed soles.

2. The method for integrally forming a polymer foam material and a solid sole in a mold according to claim 1, characterized in that: In the step S2, the sole material is a solid sole material that is vulcanized once, and the midsole protection material is a polymer prototype foam material that is foamed by a polymer foam material. The solid sole material that is vulcanized once and attached with adhesive is placed in the mold cavity (42), and then the polymer prototype foam material is placed in it. Then, the upper mold base (1) and the lower mold base (2) are molded together, and the protrusion (32) of the first insert (3) is correspondingly embedded in the mold cavity (42) and pressed together; and then the subsequent steps are performed to achieve the production of the sole formed by one-time molding.

3. The method for integrally forming a polymer foam material and a solid sole in a mold according to claim 1, characterized in that: In the step S2, the sole material is an unvulcanized synthetic rubber sole material, and the midsole protective material is a polymer synthetic material with a foaming material. The unvulcanized synthetic rubber sole material is first placed in the mold cavity (42), and then the polymer synthetic material with a foaming material is placed. Then, the upper mold base (1) and the lower mold base (2) are molded together, and the protrusion (32) of the first insert (3) is correspondingly embedded in the mold cavity (42) and pressed together; and then the subsequent steps are performed to achieve the production of a molded sole.

4. The method for integrally forming a polymer foam material and a solid sole in a mold according to claim 1, characterized in that: In step S4, the upper die base (1) and the lower die base (2) are also cooled and heat is dissipated.

5. A mold suitable for integrally forming polymer foam materials and solid soles, characterized in that: The mold comprises an upper mold base (1), a lower mold base (2), a first insert (3) assembled on the upper mold base (1) and capable of replacement, and a second insert (4) assembled on the lower mold base (2) and capable of replacement; the first insert (3) is provided with a protrusion (32), the protrusion (32) comprising a first outer wall (321) that is convex, a first inner wall (322) that is opposite to the first outer wall (321) and is concave, and a first flow channel (323), the first flow channel (323) being located at the first The outer wall (321) and the first inner wall (322) are connected to each other or attached to the surface of the first inner wall (322); the first flow channel (323) is connected to the first steam water channel (11) to form a heating circuit system, and the sole is formed by heat conduction through the protrusion (32); the second insert (4) is provided with a mold cavity (42), and the mold cavity (42) includes a second outer wall (421) that is convex, a second inner wall (422) that is opposite to the second outer wall and is concave, and a second flow channel (423). The second flow channel (423) is located between the second outer wall (421) and the second inner wall (422) or is attached to the surface of the second outer wall (421); the second flow channel (423) is connected to the second steam water channel (21) to form a heating circuit system, and the sole is formed by heat conduction through the mold cavity (42); and the lower mold base (2) is also provided with a vacuum cavity (22), and the second outer wall (421) of the mold cavity (42) protrudes into the vacuum cavity (22), and is partially formed on the mold cavity (42). A ventilation portion (424) is provided, and the ventilation portion (424) is communicated with the vacuum chamber (22) so that air in the mold cavity (42) can be extracted through the vacuum chamber (22); when the upper mold base (1) and the lower mold base (2) are closed, the protrusion (32) is correspondingly embedded in the mold cavity (42) and pressed together for heating and pressurizing the sole; the shape of the protrusion (32) and the mold cavity (42) matches the shape of the sole to be produced, and corresponding patterns are provided on the second inner wall (422) of the mold cavity (42).

6. The mold suitable for integrally forming a polymer foam material and a solid sole according to claim 5, characterized in that: The first insert (3) and the second insert (4) are formed by printing using 3D metal printing technology. The shapes of the protrusion (32) and the mold cavity (42) match the shape of the sole to be produced. The first flow channel (323) is printed and produced according to the shape of the protrusion, and the second flow channel (423) is printed and produced according to the shape of the mold cavity. The interior of the upper mold base (1) is also provided with a first cooling flow channel (13), and the peripheral wall of the lower mold base (2) is also provided with a second cooling flow channel (26). The first cooling flow channel (13) and the second cooling flow channel (26) are used to introduce cooling liquid to dissipate heat to the upper mold base and the lower mold base respectively.

7. The mold suitable for integrally forming a polymer foam material and a solid sole according to claim 5 or 6, characterized in that: The first insert (3) is embedded in a first assembly groove (12) preset on the upper die base (1), and the first insert (3) also has a first overlap edge (31) expanding outward from the four sides of the protrusion (32). The notch of the first assembly groove (12) is provided with a first receiving groove (121) expanding outward. When the first insert is embedded in the first assembly groove, the first overlap edge is embedded in the first receiving groove and is locked with screws. The first flow channel (323) is connected to the first steam water channel (11) at the junction of the first overlapping edge and the first receiving groove, and the first steam water channel (11) extends to the upper mold base (1); or the first flow channel (323) is connected to the first steam water channel (11) outside the upper mold base (1), and the first flow channel (323) extends from the upper mold base (1) through a first extension joint or an additional first external tube constructed by local extension printing of the first overlapping edge (31), and the upper mold base (1) is provided with a first recessed portion (14) for matching the first extension joint or the first external tube; the outer end of the first extension joint or the first external tube is directly connected to the first steam water channel (11).

8. The mold suitable for integrally forming a polymer foam material and a solid sole according to claim 5 or 6, characterized in that: The second insert (4) is embedded in a second assembly groove (23) preset on the lower mold base (2), and the second assembly groove (23) is an inner groove with an opening facing upward; the air permeable portion (424) on the second insert (4) is constructed by air permeable steel embedded during 3D printing, and the second insert (4) and the peripheral wall of the second assembly groove (23) enclose a vacuum chamber (22); the second insert (4) also has a second lap edge (41) expanding outward from the four sides of the mold cavity (42), and the notch of the second assembly groove (23) is provided with a second receiving groove (231) expanding outward, and when the second insert (4) is embedded in the second assembly groove, the second lap edge (41) is embedded in the second receiving groove (231) and is locked with screws; The second flow channel (423) is connected to the second steam water channel (21) at the junction of the second overlap edge and the second receiving groove, and the second steam water channel (21) extends to the lower mold base (2); or the second flow channel (423) is connected to the second steam water channel (21) outside the lower mold base (2), and the second flow channel (423) extends from the lower mold base (2) through a second extension joint or an additional second external tube constructed by local extension printing of the second overlap edge (41), and the lower mold base (2) is provided with a second recessed portion (27) in which the second extension joint or the second external tube is embedded; the outer end of the second extension joint or the second external tube is directly connected to the second steam water channel (21).

9. The mold suitable for integrally forming a polymer foam material and a solid sole according to claim 8, characterized in that: The lower mold base (2) is constructed by combining a middle frame (24) and a back plate (25). One end of the middle frame (24) abuts against and is locked on the back plate (25). The inner hollow portion of the middle frame (24) forms a second assembly groove (23). A vacuum hole (251) communicating with the vacuum chamber (22) is provided on the back plate (25).

10. The mold suitable for integrally forming a polymer foam material and a solid sole according to claim 8, characterized in that: The diameter of the ventilation holes of the ventilation portion (424) is between 50 μm and 200 μm; the ventilation portion (424) and the second flow channel (423) are arranged in a staggered manner so as not to interfere with each other.

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