Integrally-formed seven-color rainbow foaming sole and forming process
By using a 3D printing selective laser sintering device and 316L stainless steel molds, the problem of zoning accuracy in multi-color foamed soles was solved, enabling the one-piece molding of a seven-color rainbow sole, improving product quality and environmental friendliness, and reducing costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2023-12-26
- Publication Date
- 2026-04-03
AI Technical Summary
In the existing technology, multi-color foamed shoe soles cannot be foamed and molded in one step, which has problems such as quality risks, complicated processes, high prices, and environmental non-environmental protection. In addition, the molds cannot meet the requirements of zoning precision, which makes the segmented pieces easy to deform or break during the heating and pressurization process.
A 3D precision-carved mold is made using a 3D printing selective laser sintering device, with 316L stainless steel as the mold material. Combined with the segmented design, a seven-color rainbow effect is achieved through one-time foaming molding. The 3D precision-carved mold maintains the integrity of the segmented pieces under high pressure, and a multi-colored sole is formed through an integrated molding process.
This technology enables the one-piece molding of multi-colored soles, improving product quality and cleanliness, reducing costs, minimizing environmental pollution, simplifying the manufacturing process, and enhancing comfort and aesthetics.
Smart Images
Figure CN121774282A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of shoe sole molding technology, specifically to a one-piece molded seven-color rainbow foam shoe sole and its molding process. Background Technology
[0002] The style and comfort of shoes largely stem from the sole. Different sole materials and processes determine the aesthetics and comfort of a shoe. Traditional sole materials include rubber, polyurethane (PU), tendon, TPU, and various other materials. With the rise of the sports industry, the variety of sole materials has also increased, from conventional foam soles to various foam materials with different properties and standards, such as EVA foam, PU foam, and supercritical foam. More importantly, based on the increasingly mature foaming technology, a variety of foam sole series have been developed, including single-stage foaming, double-stage foaming, single-color foaming, and two-color foaming.
[0003] However, there are currently no one-piece molded multi-colored foam soles on the market, mainly because the molds cannot be divided into sections. Partitioning the mold requires using dividing pieces to separate different areas. Existing technology typically uses conventional sand casting molding processes to produce molds for foam soles, but these processes cannot meet the precision standards required for the dividing pieces. Furthermore, the metal material used in conventional sand casting molds is not hard enough; during the heating and pressurization process, the dividing pieces can be bent or broken by the mold pressure.
[0004] In existing technologies, different colors are achieved by applying or attaching other decorative accessories, or by spraying paint onto the sole. These methods pose significant quality risks, including potential defects in the quality of the shoes themselves and the potential harm of the paint to the human body.
[0005] Because existing multi-colored shoe soles are not formed in a single foaming process, the main problems include: potential quality issues, complex processes, high prices, insufficient aesthetics, inadequate comfort, and lack of environmental friendliness. To solve these problems, especially the issues of potential quality issues, high prices, and lack of environmental friendliness, solutions are needed in materials, processes, and molds. This would allow for a single foaming process, addressing the critical technical challenge of simultaneously producing multiple colors in the shoe sole. Summary of the Invention
[0006] The present invention aims to provide a one-piece molded seven-color rainbow foam sole and molding process. The technical problems to be solved include at least how to complete the seven-color rainbow foam sole through one-time foaming molding. The seven-color rainbow foam sole is beautiful, inexpensive, has no quality problems, and is highly comfortable.
[0007] To achieve the above objectives, the present invention provides a one-piece molded seven-color rainbow foam sole, comprising a first color region, a second color region, a third color region, a fourth color region, a fifth color region, a sixth color region, a seventh color region, and a midsole. The first, second, third, fourth, fifth, sixth, and seventh color regions are all located below the midsole. The fourth color region and the midsole are formed by foaming the same colored raw material, resulting in a T-shaped structure in longitudinal section. The first, second, third, fifth, sixth, and seventh color regions are respectively cross-linked with the midsole through foaming with different colored foaming materials. A first interval region exists between the first and second color regions; a second interval region exists between the second and third color regions; a third interval region exists between the third and fourth color regions; a fourth interval region exists between the fourth and fifth color regions; a fifth interval region exists between the fifth and sixth color regions; and a sixth interval region exists between the sixth and seventh color regions.
[0008] Preferably, the colors of the first color region, the second color region, the third color region, the fourth color region, the fifth color region, the sixth color region, and the seventh color region are all different.
[0009] Preferably, the first color region is red, the second color region is orange, the third color region is yellow, the fourth color region is green, the fifth color region is cyan, the sixth color region is blue, and the seventh color region is purple.
[0010] Preferably, the first color region is purple, the second color region is blue, the third color region is cyan, the fourth color region is green, the fifth color region is yellow, the sixth color region is orange, and the seventh color region is red.
[0011] Preferably, the width of the first interval region, the second interval region, the third interval region, the fourth interval region, the fifth interval region and the sixth interval region is 0.4 mm to 1.2 mm.
[0012] Preferably, the height of the first, second, third, fourth, fifth, and sixth intervals is less than or equal to 20 millimeters.
[0013] Preferably, the height of the first, second, third, fourth, fifth, and sixth intervals is 7 to 14 millimeters.
[0014] Preferably, in the foaming process of the one-piece molded seven-color rainbow foam sole, the mold used includes a bottom cover, a middle plate, and a top cover. A lower mold is located in the center of the bottom cover, and an aluminum mold is located in the center of the middle plate. The lower mold includes a forefoot area, a midfoot area, and a heel area. The forefoot area and midfoot area are separated by a first dividing piece; the midfoot area and heel area are separated by a second dividing piece. The forefoot area has a first, second, and third partition, separated by a third dividing piece; the second and third partitions are separated by a fourth dividing piece; the first dividing piece is located between the third partition and the midfoot area. The heel area has a fourth, fifth, and sixth partition, separated by a fifth dividing piece; the fifth and sixth partitions are separated by a sixth dividing piece; the second dividing piece is located between the fourth partition and the midfoot area.
[0015] Preferably, when the bottom cover, middle plate, and top cover are stacked and assembled together from bottom to top, the aluminum mold is located directly above the lower mold.
[0016] Preferably, the thickness of the first segment, the second segment, the third segment, the fourth segment, the fifth segment, and the sixth segment is 1.02 mm to 1.7 mm.
[0017] Preferably, the height of the first, second, third, fourth, fifth, and sixth segmented pieces is less than or equal to 20 millimeters.
[0018] Preferably, the height of the first, second, third, fourth, fifth, and sixth segmented pieces is 7 to 14 millimeters.
[0019] Preferably, the first segment includes a first vertical segment, a first curved segment, and a second vertical segment, which are connected sequentially.
[0020] Preferably, the second segment comprises an upper vertical segment, a second curved segment, and a lower vertical segment, which are connected sequentially.
[0021] Preferably, the third segment includes an upper vertical segment, a curved segment, and a lower vertical segment, which are connected sequentially.
[0022] Preferably, the fourth segment includes an upper vertical segment, a curved segment, and a lower vertical segment, which are connected sequentially.
[0023] Preferably, the fifth segment includes an upper vertical segment, a curved segment, and a lower vertical segment, which are connected sequentially.
[0024] Preferably, the sixth segment includes an upper vertical segment, a curved segment, and a lower vertical segment, which are connected sequentially.
[0025] Preferably, the mold used in the foaming process of the one-piece molded seven-color rainbow foam sole is a 3D precision carving mold made by a 3D printing selective laser sintering device.
[0026] Preferably, the 3D printing selective laser sintering device includes a forming cavity, a scanning system, a powder feeding system, a powder spreading system, a laser protective mirror, a piston, and a substrate. The laser protective mirror is disposed at the top of the forming cavity; the scanning system is disposed above the laser protective mirror; the powder feeding system is disposed below the forming cavity for conveying metal powder into the interior of the forming cavity; the piston is disposed below the forming cavity and located on one side of the powder feeding system; the substrate is disposed on the upper surface of the piston; the piston can drive the substrate to move up and down; the powder spreading system is disposed inside the forming cavity for spreading the metal powder conveyed to the interior of the forming cavity by the powder feeding system onto the upper surface of the substrate; the scanning system uses a laser as an energy source, scans the metal powder bed on the upper surface of the substrate layer by layer through the laser protective mirror and according to the path planned in the 3D CAD slicing model, and the scanned metal powder melts and solidifies to achieve a metallurgical bonding effect, ultimately obtaining the 3D precision-carved mold designed by the 3D CAD slicing model.
[0027] Preferably, a protective gas inlet is provided on one side of the molding cavity, and a protective gas outlet is provided on the other side; the protective gas inlet is used to introduce protective gas into the interior of the molding cavity; the protective gas outlet is used to discharge the protective gas to the outside of the molding cavity.
[0028] Preferably, the protective gas inlet is located at an upper position on one side wall of the molding cavity; the protective gas outlet is located at a lower position on the other side wall of the molding cavity.
[0029] Preferably, the powder spreading system is a roller that can roll left and right inside the molding cavity.
[0030] Preferably, the substrate and the 3D engraving mold are surrounded by loose metal powder.
[0031] Preferably, there are two powder feeding systems, which are symmetrically distributed on the left and right sides of the piston.
[0032] Preferably, there are two powder spreading systems, and the positions of the two powder spreading systems correspond to the positions of the two powder feeding systems, respectively.
[0033] This invention also provides a molding process for a one-piece seven-color rainbow foam sole, comprising the following steps: S1. First, place the first material of the sole foam in the first section of the forefoot area of the lower mold, the second material of the sole foam in the second section, and the third material of the sole foam in the third section; place the fourth material of the sole foam in the fourth section of the heel area of the lower mold, the fifth material of the sole foam in the fifth section, and the sixth material of the sole foam in the sixth section; then close the middle plate so that the middle plate is stacked on top of the bottom cover, at which time the aluminum mold is located directly above the lower mold; S2. The seven raw materials for shoe sole foaming are introduced into the middle area of the aluminum mold and the lower mold; then the upper cover is closed, so that the bottom cover, the middle plate and the upper cover are stacked and assembled from bottom to top; the bottom cover, the middle plate and the upper cover are applied to the assembled bottom cover, the middle plate and the upper cover at a predetermined first time through the hydraulic equipment, and the seven foaming materials in the 3D fine carving mold are heated to the predetermined first temperature and maintained for a predetermined first time, so that the seven foaming materials reach a semi-foamed state; S3. Separate the bottom cover, mid plate, and top cover. Separate the semi-foamed midsole from the aluminum mold. After removing the middle mid plate, reassemble the top cover and bottom cover seamlessly. Then, apply a predetermined second pressure and a predetermined second temperature to the assembled top cover and bottom cover within a predetermined second time period. This allows the seven different colored foaming materials to fully foam, ultimately forming the one-piece molded seven-color rainbow foamed sole.
[0034] Preferably, before injecting the foaming materials 1, 2, 3, 4, 5, 6 and 7 into the shoe sole, a release agent is first applied to the forefoot area, middle area, heel area of the shoe sole, as well as the walls of the aluminum mold, the first segment, the second segment, the third segment, the fourth segment, the fifth segment and the sixth segment of the shoe sole in the lower mold.
[0035] Preferably, the predetermined first time is 25 to 45 seconds.
[0036] Preferably, the predetermined first pressure is 100 kg to 140 kg.
[0037] Preferably, the predetermined first temperature is set between 165°C and 185°C.
[0038] Preferably, the predetermined second time is 450 seconds.
[0039] Preferably, the predetermined second pressure is 100 kg to 140 kg.
[0040] Preferably, the predetermined second temperature is set between 165°C and 185°C.
[0041] Compared with the prior art, the beneficial effects of the present invention are: The molding process of the one-piece molded seven-color rainbow foam sole described in this invention is a one-piece molding foaming process. Instead of combining various parts by means of glue, buckles, etc., it is molded in one piece by closing three molds (upper, middle, and lower). This results in higher product quality, higher cleanliness, higher aesthetics, and a lower price (reduced processes, equipment, and personnel). It also meets higher environmental standards and requirements, resulting in less pollution and obvious advantages.
[0042] The one-piece molded seven-color rainbow foam sole is also made with a single color throughout the manufacturing process, rather than achieving a multi-color effect through other methods such as spraying, electroplating, or printing.
[0043] The one-piece molded seven-color rainbow foam sole has various colors of materials adjusted before production. Different colors of foam material are poured into the mold respectively. It is very clear and simple, and the process is relatively simple, making it convenient for ordinary workers to operate. Attached Figure Description
[0044] The accompanying drawings are provided to further understand the technical solutions of the present invention and constitute a part of the specification. They are used together with the specific embodiments of this application to explain the technical solutions of the present invention and do not constitute a limitation on the technical solutions of the present invention.
[0045] Figure 1 This is a top view of the lower mold described in this invention.
[0046] Figure 2 This is a schematic diagram of the structure of the bottom cover, middle plate and top cover assembled together according to the present invention.
[0047] Figure 3 This is a schematic diagram of the one-piece molded seven-color rainbow foam shoe sole described in this invention.
[0048] Figure 4This is a schematic diagram of the 3D printing selective laser sintering device described in this invention. Implementation
[0049] The invention is described in more detail below to aid in understanding it.
[0050] like Figures 1 to 3 As shown, the one-piece molded seven-color rainbow foam sole of the present invention includes a first color area 101, a second color area 102, a third color area 103, a fourth color area 104, a fifth color area 105, a sixth color area 106, a seventh color area 107, and a midsole 108. The first color area 101, second color area 102, third color area 103, fourth color area 104, fifth color area 105, sixth color area 106, and seventh color area 107 are all located below the midsole 108. The fourth color area 104 and the midsole 108 are T-shaped structures formed by foaming raw materials of the same color. The first color area 101, second color area 102, third color area 103, fifth color area 104, fifth color area 105, sixth color area 106, seventh color area 107, and seventh color area 108 are all located below the midsole 108. Region 105, the sixth color region 106, and the seventh color region 107 are foamed and cross-linked with the midsole 108 using foaming materials of different colors; a first interval region 1021 exists between the first color region 101 and the second color region 102; a second interval region 1023 exists between the second color region 102 and the third color region 103; a third interval region 1034 exists between the third color region 103 and the fourth color region 104; a fourth interval region 1045 exists between the fourth color region 104 and the fifth color region 105; a fifth interval region 1056 exists between the fifth color region 105 and the sixth color region 106; and a sixth interval region 1067 exists between the sixth color region 106 and the seventh color region 107.
[0051] Preferably, the colors of the first color region 101, the second color region 102, the third color region 103, the fourth color region 104, the fifth color region 105, the sixth color region 106, and the seventh color region 107 are all different.
[0052] Preferably, the color of the first color region 101 is red, the color of the second color region 102 is orange, the color of the third color region 103 is yellow, the color of the fourth color region 104 is green, the color of the fifth color region 105 is cyan, the color of the sixth color region 106 is blue, and the color of the seventh color region 107 is purple.
[0053] Preferably, the color of the first color region 101 is purple, the color of the second color region 102 is blue, the color of the third color region 103 is cyan, the color of the fourth color region 104 is green, the color of the fifth color region 105 is yellow, the color of the sixth color region 106 is orange, and the color of the seventh color region 107 is red.
[0054] Preferably, the widths of the first interval 1021, the second interval 1023, the third interval 1034, the fourth interval 1045, the fifth interval 1056, and the sixth interval 1067 are 0.4 mm to 1.2 mm.
[0055] Preferably, the height of the first interval 1021, the second interval 1023, the third interval 1034, the fourth interval 1045, the fifth interval 1056 and the sixth interval 1067 is less than or equal to 20 mm.
[0056] Preferably, the height of the first interval 1021, the second interval 1023, the third interval 1034, the fourth interval 1045, the fifth interval 1056 and the sixth interval 1067 is 7 mm to 14 mm.
[0057] The one-piece molded seven-color rainbow foam sole of the present invention uses a mold including a bottom cover 11, a middle plate 12, and a top cover 13 during the foaming process. A lower mold 111 is disposed in the middle of the bottom cover 11, and an aluminum mold 121 is disposed in the middle of the middle plate 12. The lower mold 111 includes a forefoot area 1, a middle area 2, and a heel area 3. The forefoot area 1 and the middle area 2 are separated by a first dividing piece 4; the middle area 2 and the heel area 3 are separated by a second dividing piece 5. The forefoot area 1 is provided with a first partition 1001, a second partition 1002, and a third partition 1003. The first partition 1001... 001 and the second section 1002 are separated by a third dividing piece 6; the second section 1002 and the third section 1003 are separated by a fourth dividing piece 7; the first dividing piece 4 is disposed between the third section 1003 and the middle section 2; the heel area 3 of the sole is provided with a fourth section 1005, a fifth section 1006 and a sixth section 1007, the fourth section 1005 and the fifth section 1006 are separated by a fifth dividing piece 8; the fifth section 1006 and the sixth section 1007 are separated by a sixth dividing piece 9; the second dividing piece 5 is disposed between the fourth section 1005 and the middle section 2.
[0058] Preferably, when the bottom cover 11, the middle plate 12 and the top cover 13 are stacked and assembled together from bottom to top, the aluminum mold 121 is located directly above the lower mold 111.
[0059] Preferably, the thickness of the first segment 4, the second segment 5, the third segment 6, the fourth segment 7, the fifth segment 8 and the sixth segment 9 is 0.4 mm to 1.2 mm.
[0060] Preferably, the height of the first segment 4, the second segment 5, the third segment 6, the fourth segment 7, the fifth segment 8, and the sixth segment 9 is less than or equal to 20 mm.
[0061] Preferably, the height of the first segment 4, the second segment 5, the third segment 6, the fourth segment 7, the fifth segment 8, and the sixth segment 9 is 7 mm to 14 mm.
[0062] Preferably, the first segment 4 includes a first vertical segment 41, a first curved segment 42, and a second vertical segment 43, which are connected in sequence.
[0063] Preferably, the second segment 5 includes an upper vertical segment 51, a second curved segment 52, and a lower vertical segment 53, which are connected in sequence.
[0064] Preferably, the third segment 6 includes an upper vertical segment 61, a curved segment 62, and a lower vertical segment 63, which are connected in sequence.
[0065] Preferably, the fourth segment 7 includes an upper vertical segment 701, a curved segment 702, and a lower vertical segment 703, which are connected in sequence.
[0066] Preferably, the fifth segment 8 includes an upper vertical segment 801, a curved segment 802, and a lower vertical segment 803, which are connected in sequence.
[0067] Preferably, the sixth segment 9 includes an upper vertical segment 91, a curved segment 92, and a lower vertical segment 93, which are connected in sequence.
[0068] In the existing technology, the molds used for two-color foam soles do not require the setting of dividing pieces, so they can be manufactured using conventional sand casting molding processes.
[0069] The standard process for sand casting molds is as follows: Step 1: Carve the wooden model according to the drawings; The second step is to make a plaster mold based on the wooden mold using sand casting. The plaster mold is hollow inside. The third step is to heat the metal material, such as aluminum, iron or copper, and pour the liquid metal material formed after heating into the plaster mold to cool and solidify. Step 4: Remove the outer shell and then take out the metal mold blank inside; The fifth step is to clean the initial mold, then carve it according to the 3D drawings, carving out the details and patterns. After that, it is polished and refined to obtain a standard metal mold for shoe soles.
[0070] Since two-color foam soles do not have many requirements for molds, and the bottom mold in the mold does not have the division of color block areas, there are only two colors, the top and bottom. Therefore, there is no problem of setting color block areas in the bottom mold. There are also no more requirements for conventional foaming technology. As long as the temperature, time and pressure reach certain values, the entire foaming process of the two-color sole raw materials can be completed.
[0071] The requirements for molds in multi-color foam soles differ from those in two-color foam soles. Molds for multi-color foam soles need to be divided into different color areas, separated by dividing pieces (i.e., the first dividing piece 4 and the second dividing piece 5). The materials used in conventional sand casting molding processes do not meet the standard requirements for these dividing pieces. The basic standard thickness of the dividing pieces in the molds for multi-color foam soles is approximately 0.4 mm to 1.2 mm, and the height can range from 7 to 14 mm, with some soles even reaching 20 mm. Conventional sand casting molding processes cannot achieve this precision, and the metal materials used in conventional molds lack the necessary hardness. Due to insufficient hardness, these dividing pieces will bend or break under the pressure of the mold during the heating and pressing process, making it impossible to produce multi-color foam soles. If seven colors of raw materials are used for foaming, the bending or breaking of the dividing pieces will cause the seven colors to mix, failing to address the issues of cleanliness, quality, and high comfort required by this application.
[0072] To solve the above problems, the mold used in the foaming process of the one-piece molded seven-color rainbow foam sole of the present invention is a 3D precision carving mold made by a 3D printing selective laser sintering device.
[0073] Selective Laser Melting (SLM) is a major technique in additive manufacturing of metal materials. This technology uses a laser as the energy source, scanning layer by layer through a bed of metal powder according to a pre-planned path in a 3D CAD slicing model. The scanned metal powder melts and solidifies to achieve a metallurgical bond, ultimately producing the metal part designed in the model. The melting precision of the metal alloy powder is between 0.2 and 0.8 mm (because the surface roughness of 316L stainless steel powder can reach 8 micrometers, or 8 μm), making it fully capable of melting 1 mm thick slices. Furthermore, due to the hardness of the metal alloy powder, even 1 mm thick slices or columns 10 mm high can withstand hundreds of kilograms of pressure from a press without bending or breaking, thus fully meeting the requirements for multi-colored shoe sole foaming.
[0074] like Figure 4 As shown, the 3D printing selective laser sintering device includes a forming cavity 71, a scanning system 72, a powder feeding system 73, a powder spreading system 74, a laser protective mirror 75, a piston 78, and a substrate 79. The laser protective mirror 75 is disposed at the top of the forming cavity 71; the scanning system 72 is disposed above the laser protective mirror 75; the powder feeding system 73 is disposed below the forming cavity 71 and is used to transport metal powder into the interior of the forming cavity 71; the piston 78 is disposed below the forming cavity 71 and located to one side of the powder feeding system 73; the substrate 79 is disposed on the upper surface of the piston 78; the piston 78 can drive the substrate 79 to move up and down; the powder spreading system 74 is disposed inside the forming cavity 71 and is used to spread the metal powder transported to the interior of the forming cavity 71 by the powder feeding system 73 onto the upper surface of the substrate 79; the scanning system 72 uses a laser as an energy source, scanning through the laser protective mirror 75 and according to 3D CAD... The planned path in the slicing model is scanned layer by layer on the metal powder bed on the upper surface of the substrate 79. The scanned metal powder is melted and solidified to achieve a metallurgical bonding effect, and finally the 3D precision carving mold 81 designed by the three-dimensional CAD slicing model is obtained.
[0075] Preferably, a protective gas inlet 76 is provided on one side of the molding cavity 71, and a protective gas outlet 77 is provided on the other side; the protective gas inlet 76 is used to introduce protective gas into the interior of the molding cavity 71; the protective gas outlet 77 is used to discharge the protective gas to the outside of the molding cavity 71.
[0076] Preferably, the protective gas inlet 76 is located at an upper position on one side wall of the molding cavity 71; the protective gas outlet 77 is located at a lower position on the other side wall of the molding cavity 71.
[0077] Preferably, the powder spreading system 74 is a roller that can roll left and right inside the forming cavity 71.
[0078] Preferably, the substrate 79 and the 3D engraving mold 81 are surrounded by loose metal powder 80.
[0079] Preferably, there are two powder feeding systems 73, which are symmetrically distributed on the left and right sides of the piston 78.
[0080] Preferably, there are two powder spreading systems 74, and the positions of the two powder spreading systems 74 correspond to the positions of the two powder feeding systems, respectively.
[0081] During the fabrication of a 3D precision mold using the aforementioned 3D printing selective laser sintering device, the powder feeding system 73 can move up and down. The upward movement of the powder feeding system 73 delivers metal powder into the interior of the molding cavity 71. The left and right rolling of the powder spreading system 74 inside the molding cavity 71 spreads the metal powder delivered by the powder feeding system 73 onto the upper surface of the substrate 79. The layer-by-layer scanning of the scanning system 72 melts the metal powder on the upper surface of the substrate 79, and then the molten metal powder solidifies to achieve a metallurgical bonding effect, ultimately obtaining the 3D precision mold 81 designed by the three-dimensional CAD slice model.
[0082] The structural properties of the metal material used to manufacture the 3D precision-carved mold differ from existing technologies. In existing technologies, the metal materials used in conventional sand casting mold processes are typically aluminum, iron, or copper. These materials are not particularly hard, and under certain pressure and temperature, they must be in large, bulky shapes, not as tiny dots or columns (1 mm in diameter). Thin shapes would be bent or broken during conventional shoe sole molding. Therefore, conventional mold metal materials, such as aluminum, iron, and copper, cannot meet the required precision and hardness of the seven-color mold. Only new metal alloy powders are suitable. The metal powder material used in this application for manufacturing the 3D precision-carved mold is 316L stainless steel. 316L stainless steel contains molybdenum, iron, chromium, nickel, and other elements. The presence of chromium and nickel improves the material's corrosion resistance and mechanical properties. 316L stainless steel contains molybdenum, and its overall performance is superior to that of 310 and 304 stainless steel. 316L stainless steel also has good resistance to chloride corrosion, so it is usually used in marine environments.
[0083] The characteristics of 316L stainless steel include: 1) Cold-rolled products have a good gloss and a beautiful appearance; 2) Due to the addition of Mo, it exhibits excellent corrosion resistance, especially resistance to pitting corrosion; 3) Excellent high-temperature strength; 4) Possesses excellent work hardening properties (weak magnetism after processing); 5) It is non-magnetic in the solid solution state; 6) It is more expensive than 304 stainless steel.
[0084] This invention also provides a molding process for a one-piece seven-color rainbow foam sole, comprising the following steps: S1. First, place the first material of the sole foam (e.g., red) in the first section 1001 of the forefoot area 1 of the lower mold 111, place the second material of the sole foam (e.g., orange) in the second section 1002, and place the third material of the sole foam (e.g., yellow) in the third section 1003; place the fourth material of the sole foam (e.g., cyan) in the fourth section 1005 of the heel area 3 of the lower mold 111, place the fifth material of the sole foam (e.g., blue) in the fifth section 1006, and place the sixth material of the sole foam (e.g., purple) in the sixth section 1007; then close the middle plate 12, so that the middle plate 12 is stacked on top of the bottom cover 11, at which time the aluminum mold 121 is located directly above the lower mold 111; S2. Introduce the seven foaming materials (such as green) into the middle area 2 of the aluminum mold 121 and the lower mold 111; then cover the upper cover 13, so that the bottom cover 11, the middle plate 12 and the upper cover 13 are stacked and assembled from bottom to top; apply a predetermined first pressure (the mold closing pressure is 100-140 kg) and a predetermined first temperature (generally set between 165-185 degrees) to the assembled bottom cover 11, the middle plate 12 and the upper cover 13 within a predetermined first time (generally each press time is between 25-45 seconds) using a hydraulic press. First, heat the seven foaming materials (i.e., raw material one, raw material two, raw material three, raw material four, raw material five, raw material six and raw material seven) in the 3D carving mold to the predetermined first temperature and maintain it for a predetermined first time. At this time, the temperature is not enough to make the seven foaming materials fully foam, that is, in a semi-foamed state. S3. Separate the bottom cover 11, the middle plate 12, and the top cover 13. Separate the semi-foamed midsole 108 from the aluminum mold 121. After removing the middle plate 12, reassemble the top cover 13 and the bottom cover 11 seamlessly. Then, within a predetermined second time (approximately 450 seconds), apply a predetermined second pressure (100-140 kg) and a predetermined second temperature (between 165°C and 185°C) to the assembled top cover 13 and bottom cover 11. This allows the seven different colored foaming materials (i.e., raw material one, raw material two, raw material three, raw material four, raw material five, raw material six, and raw material seven) to be fully foamed, ultimately forming the one-piece molded seven-color rainbow foamed shoe sole described in this invention.
[0085] Preferably, before injecting the foaming materials 1, 2, 3, 4, 5, 6, and 7 into the shoe sole, a release agent is first applied to the walls of the forefoot area 1, middle area 2, heel area 3 of the shoe sole, as well as the aluminum mold 121, the first segment 4, the second segment 5, the third segment 6, the fourth segment 7, the fifth segment 8, and the sixth segment 9 of the lower mold 111.
[0086] The molding process proposed in this invention is one-piece foam molding, rather than creating a one-piece seven-color rainbow foam sole by combining outsole components and spraying outsole components.
[0087] Firstly, this method is a one-piece molding foaming process, which does not combine various parts through adhesives, snaps, or other means. Instead, it is molded as a single piece by closing three molds (upper, middle, and lower). This results in higher product quality, cleaner products, and more aesthetically pleasing products, while also being cheaper (due to fewer processes, fewer equipment, and fewer personnel). Furthermore, it meets higher environmental standards and requirements, resulting in less pollution and other significant advantages.
[0088] The one-piece molded seven-color rainbow foam sole is also made with a single color throughout the manufacturing process, rather than achieving the seven-color effect through other methods such as spraying, electroplating, or printing.
[0089] The one-piece molded seven-color rainbow foam sole has various colors of material adjusted before production. Different colors of foam material are poured into the mold respectively. It is very clear and simple, and the process is relatively simple and convenient for ordinary workers to operate. If it is a spraying, printing or other process, then professional technicians and professional equipment are required to operate.
[0090] While spraying can achieve a variety of colors, it requires additional labor, equipment, and costs. More alarmingly, the spraying materials are chemical raw materials, which are polluting and toxic, posing a risk to workers operating without automated equipment. Furthermore, without automated equipment, the operators must be skilled workers, because any deviation will result in inconsistent shoe colors and product quality.
[0091] The one-piece molded seven-color rainbow foam sole of this invention utilizes a variety of novel technologies and materials, including: 1. The shoe sole mold uses a new type of metal alloy powder material (i.e., 316L stainless steel). 2. The shoe sole mold forming process utilizes a novel 3D printing selective laser sintering technology; 3. The seven-color shoe sole mold utilizes design zoning and one-piece molding technology.
[0092] The advantages of this invention include: 1. Higher quality; 2. More environmentally friendly and healthier; 3. The process is simpler and more efficient; 4. More cost-effective; 5. Greater comfort; 6. The design is more stylish and fashionable; 7. The molding and application technology is more advanced.
[0093] The preferred embodiments of the present invention have been described above, but are not intended to limit the invention. Those skilled in the art can make modifications and variations to the embodiments disclosed herein without departing from the scope and spirit of the invention.
Claims
1. A one-piece molded seven-color rainbow foam sole, characterized in that, The one-piece molded seven-color rainbow foam sole includes a first color area, a second color area, a third color area, a fourth color area, a fifth color area, a sixth color area, a seventh color area, and a midsole. The first, second, third, fourth, fifth, sixth, and seventh color areas are all located below the midsole. The fourth color area and the midsole are formed by foaming the same colored raw material, resulting in a T-shaped cross-section. The first, second, third, fifth, sixth, and seventh color areas are cross-linked with the midsole using different colored foaming materials. A first interval exists between the first and second color areas; a second interval exists between the second and third color areas; a third interval exists between the third and fourth color areas; a fourth interval exists between the fourth and fifth color areas; a fifth interval exists between the fifth and sixth color areas; and a sixth interval exists between the sixth and seventh color areas.
2. The one-piece molded seven-color rainbow foam sole according to claim 1, characterized in that, The colors of the first, second, third, fourth, fifth, sixth, and seventh color regions are all different.
3. The one-piece molded seven-color rainbow foam sole according to claim 1, characterized in that, The first color region is red, the second color region is orange, the third color region is yellow, the fourth color region is green, the fifth color region is cyan, the sixth color region is blue, and the seventh color region is purple.
4. The one-piece molded seven-color rainbow foam sole according to claim 1, characterized in that, The first color region is purple, the second color region is blue, the third color region is cyan, the fourth color region is green, the fifth color region is yellow, the sixth color region is orange, and the seventh color region is red.
5. The one-piece molded seven-color rainbow foam sole according to claim 1, characterized in that, The width of the first, second, third, fourth, fifth, and sixth intervals is 0.4 mm to 1.2 mm.
6. The one-piece molded seven-color rainbow foam sole according to claim 1, characterized in that, The height of the first, second, third, fourth, fifth, and sixth intervals is less than or equal to 20 millimeters.
7. The one-piece molded seven-color rainbow foam sole according to claim 1, characterized in that, The height of the first, second, third, fourth, fifth, and sixth intervals is 7 to 14 millimeters.
8. The one-piece molded seven-color rainbow foam sole according to claim 1, characterized in that, The mold used in the foaming process of the one-piece molded seven-color rainbow foam sole is a 3D precision carving mold made by a 3D printing selective laser sintering device.
9. The one-piece molded seven-color rainbow foam sole according to claim 8, characterized in that, The 3D precision-carved mold includes a bottom cover, a middle plate, and a top cover. A lower mold is disposed in the middle of the bottom cover, and an aluminum mold is disposed in the middle of the middle plate. The lower mold includes a forefoot area, a midfoot area, and a heel area of the sole. The forefoot area and the midfoot area are separated by a first dividing piece; the midfoot area and the heel area are separated by a second dividing piece; the forefoot area of the sole is provided with a first partition, a second partition, and a third partition, and the first partition and the second partition are separated by a third dividing piece. The second and third partitions are separated by a fourth partition. The first segment is positioned between the third segment and the middle segment; the heel area of the sole is provided with a fourth segment, a fifth segment, and a sixth segment, the fourth segment and the fifth segment being separated by the fifth segment; the fifth segment and the sixth segment are separated by the sixth segment. The second segment is placed between the fourth partition and the middle partition.
10. The one-piece molded seven-color rainbow foam sole according to claim 9, characterized in that, The first segment includes a first vertical segment, a first curved segment, and a second vertical segment, which are connected sequentially.