Integrally-formed seven-color rainbow foaming sole with waterproof and breathable functions

Abstract

The invention relates to an integrally formed seven-color rainbow foaming sole with waterproof and breathable functions, which comprises 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 color area, the second color area, the third color area, the fourth color area, the fifth color area, the sixth color area and the seventh color area are all located below the insole. The fourth color area and the midsole are of a structure with a T-shaped longitudinal section, and the structure is formed by foaming raw materials with the same color; the first color area, the second color area, the third color area, the fifth color area, the sixth color area and the seventh color area are respectively foamed and crosslinked with the insole through foaming raw materials with different colors; air holes extending from bottom to top are formed in the first color area, the second color area, the third color area, the fifth color area, the sixth color area and the seventh color area.

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 sole with waterproof and breathable functions. 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.

[0006] Another problem with existing foam soles is the lack of new functional foam soles, such as breathable and waterproof ones. While some functional soles are available on the market achieved through post-installation bonding or adhesives, they are not truly one-piece molded, breathable, and waterproof foam soles. Because adhesive bonding and post-installation methods still carry the risk of sole detachment, this can lead to leaks and render the shoes unwearable. Summary of the Invention

[0007] The present invention aims to provide a one-piece molded seven-color rainbow foam sole with waterproof and breathable functions. The technical problem to be solved includes at least how to manufacture the seven-color rainbow foam sole through one-time foaming molding. The seven-color rainbow foam sole has built-in small holes and breathable function. After adding a waterproof and breathable membrane, the sole has waterproof and breathable functions, is beautiful, low price, has no quality problems, and is highly comfortable.

[0008] To achieve the above objectives, this invention provides a one-piece molded seven-color rainbow foam sole with waterproof and breathable functions, comprising 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 a material of the same color, resulting in a T-shaped structure in cross-section. The first, second, third, fifth, sixth, and seventh color areas are respectively cross-linked with the midsole using foaming materials of different colors. A first interval zone exists between the first color area and the second color area; a second interval zone exists between the second color area and the third color area; a third interval zone exists between the third color area and the fourth color area; a fourth interval zone exists between the fourth color area and the fifth color area; a fifth interval zone exists between the fifth color area and the sixth color area; a sixth interval zone exists between the sixth color area and the seventh color area; and ventilation holes extending from bottom to top are provided in the first color area, the second color area, the third color area, the fifth color area, the sixth color area, the seventh color area, and the midsole.

[0009] Preferably, the diameter of the vent hole is 1 mm.

[0010] Preferably, the height of the vent hole is less than or equal to 20 mm.

[0011] Preferably, the height of the vent hole is 7 mm to 14 mm.

[0012] Preferably, the height of the vent hole is 10 mm.

[0013] Preferably, a waterproof and breathable membrane is attached to the top of the midsole.

[0014] Preferably, the waterproof and breathable membrane is attached to the top of the midsole at the location through which the breathable holes penetrate.

[0015] Preferably, the waterproof and breathable membrane is made of a polymer material.

[0016] Preferably, the polymer material includes polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), or polytetrafluoroethylene (PTFE).

[0017] Preferably, the thickness of the waterproof and breathable membrane is between 10 μm and 25 μm.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] Preferably, in the foaming process of the one-piece molded seven-color rainbow foam sole with waterproof and breathable functions, the mold used includes a bottom cover, a mid-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 mid-plate. The lower mold includes a forefoot area, a mid-section area, and a heel area. The forefoot area and mid-section are separated by a first dividing piece; the mid-section and heel area are separated by a second dividing piece. The forefoot area is further divided into a first partition, a second partition, and a third partition. The first and second partitions are separated by... The second and third sections are separated by a third dividing piece; the third and fourth sections are separated by a fourth dividing piece; the first dividing piece is located between the third section and the middle section; the heel area of ​​the sole has a fourth, fifth, and sixth section, the fourth and fifth sections are separated by a fifth dividing piece; the fifth and sixth sections are separated by a sixth dividing piece; the second dividing piece is located between the fourth section and the middle section; multiple vertical columns are provided in the first, second, third, fourth, fifth, and sixth sections.

[0023] 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.

[0024] 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.

[0025] Preferably, the diameter of the vertical column is less than or equal to 1 mm.

[0026] Preferably, the diameter of the vertical column is 0.2 mm to 0.8 mm.

[0027] Preferably, the height of the vertical column is less than or equal to 20 mm.

[0028] Preferably, the height of the vertical column is 7 mm to 14 mm.

[0029] Preferably, the height of the vertical column is 10 mm.

[0030] Preferably, the first segment includes a first vertical segment, a first curved segment, and a second vertical segment, which are connected sequentially.

[0031] Preferably, the second segment comprises an upper vertical segment, a second curved segment, and a lower vertical segment, which are connected sequentially.

[0032] Preferably, the third segment includes an upper vertical segment, a curved segment, and a lower vertical segment, which are connected sequentially.

[0033] Preferably, the fourth segment includes an upper vertical segment, a curved segment, and a lower vertical segment, which are connected sequentially.

[0034] Preferably, the fifth segment includes an upper vertical segment, a curved segment, and a lower vertical segment, which are connected sequentially.

[0035] Preferably, the sixth segment includes an upper vertical segment, a curved segment, and a lower vertical segment, which are connected sequentially.

[0036] Preferably, the mold used in the foaming process of the one-piece molded seven-color rainbow foam sole with waterproof and breathable function is a 3D precision carving mold made by a 3D printing selective laser sintering device.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] Preferably, the powder spreading system is a roller that can roll left and right inside the molding cavity.

[0041] Preferably, the substrate and the 3D engraving mold are surrounded by loose metal powder.

[0042] Preferably, there are two powder feeding systems, which are symmetrically distributed on the left and right sides of the piston.

[0043] 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.

[0044] This invention also provides a molding process for a one-piece, waterproof and breathable 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, middle plate and top cover, separate the semi-foamed insole from the aluminum mold, remove the middle plate, and then reassemble the top cover and bottom cover tightly. Apply a predetermined second pressure and a predetermined second temperature to the assembled top cover and bottom cover within a predetermined second time period, so that the seven different colored foaming materials are fully foamed and then demolded. S4. Make an oval pattern according to the position and size of the ventilation holes, and then cut out a waterproof and breathable membrane of the same size according to the size of the pattern. Then, glue the edge of the oval waterproof and breathable membrane to the top of the midsole of the shoe sole after demolding by means of adhesive, and finally form the one-piece molded seven-color rainbow foam shoe sole with waterproof and breathable function.

[0045] 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 aluminum mold, the first segment, the second segment, the third segment, the fourth segment, the fifth segment, the sixth segment and the wall of the vertical column of the lower mold.

[0046] Preferably, the predetermined first time is 25 to 45 seconds.

[0047] Preferably, the predetermined first pressure is 100 kg to 140 kg.

[0048] Preferably, the predetermined first temperature is set between 165°C and 185°C.

[0049] Preferably, the predetermined second time is 450 seconds.

[0050] Preferably, the predetermined second pressure is 100 kg to 140 kg.

[0051] Preferably, the predetermined second temperature is set between 165°C and 185°C.

[0052] Compared with the prior art, the beneficial effects of the present invention are: The one-piece molded seven-color rainbow foam sole with waterproof and breathable function described in this invention is one-piece molded. The one-piece mold is made using 3D printing technology. Because the material of the mold itself is metal alloy powder, it can be 3D printed. Moreover, the precision and hardness can be achieved to the extreme, reaching the millimeter and micrometer level. The sole has perforated, breathable and waterproof function.

[0053] The molding process of the one-piece molded seven-color rainbow foam sole with waterproof and breathable function described in this invention is a one-piece molding foaming process. Instead of combining various parts by means of glue, buckles or other methods, 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 process, reduced equipment, reduced personnel). It also meets higher environmental standards and requirements, resulting in less pollution and obvious advantages.

[0054] The one-piece molded, waterproof and breathable seven-color rainbow foam sole is also made in one color during the manufacturing process, rather than achieving a multi-color effect through other methods such as spraying, electroplating, or printing.

[0055] The one-piece molded, waterproof and breathable 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

[0056] 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.

[0057] Figure 1 This is a top view of the lower mold described in this invention.

[0058] 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.

[0059] Figure 3 This is a schematic diagram of the structure of the one-piece molded seven-color rainbow foam sole with waterproof and breathable functions described in this invention.

[0060] Figure 4 This is a schematic diagram of the 3D printing selective laser sintering device described in this invention. Implementation

[0061] The invention is described in more detail below to aid in understanding it.

[0062] like Figures 1 to 3As shown, the one-piece molded seven-color rainbow foam sole with waterproof and breathable function 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 the same colored raw material. The first color area 101, second color area 102, third color area 103, fifth color area 105, sixth color area 106, and seventh color area 107 are respectively foamed and cross-linked with the midsole 108 using different colored foaming materials. There is a gap between the first color area 101 and the second color area 102. There is a first interval zone 1021; a second interval zone 1023 is provided between the second color zone 102 and the third color zone 103; a third interval zone 1034 is provided between the third color zone 103 and the fourth color zone 104; a fourth interval zone 1045 is provided between the fourth color zone 104 and the fifth color zone 105; a fifth interval zone 1056 is provided between the fifth color zone 105 and the sixth color zone 106; a sixth interval zone 1067 is provided between the sixth color zone 106 and the seventh color zone 107; and a ventilation hole 1000 extending from bottom to top is provided in the first color zone 101, the second color zone 102, the third color zone 103, the fifth color zone 105, the sixth color zone 106, the seventh color zone 107 and the midsole 108.

[0063] Preferably, the diameter of the vent hole 1000 is 1 mm.

[0064] Preferably, the height of the vent hole 1000 is less than or equal to 20 mm.

[0065] Preferably, the height of the vent hole 1000 is 7 mm to 14 mm.

[0066] Preferably, the height of the vent hole 1000 is 10 mm.

[0067] Preferably, a waterproof and breathable membrane is bonded to the top of the midsole 108.

[0068] The aforementioned waterproof and breathable membrane enables the sole of the shoe described in this application to have both breathable and waterproof functions.

[0069] This waterproof and breathable membrane material is generally made of polymer materials, such as polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), and polytetrafluoroethylene (PTFE). Waterproof and breathable membranes made from these materials have multiple functions: A. Waterproofing: It can prevent moisture from entering the shoe cavity through the vent holes (i.e., ventilation holes 1000) on the sole. Because the waterproof and breathable membrane adopts a unique microporous structure, it can effectively block the penetration of moisture and humidity, while allowing gas and water vapor inside the shoe cavity to pass through and be discharged to the outside of the shoe cavity.

[0070] B. Breathability: The waterproof and breathable membrane has high breathability, which can ensure foot comfort and shoe breathability. Its unique microporous structure can control the release of water vapor and prevent external moisture from entering, keeping the inside of the shoe dry.

[0071] C. Durability: Waterproof and breathable membranes are wear-resistant, aging-resistant, and corrosion-resistant, and can maintain their performance and shape for a long time. They have good tensile and tear resistance and can be used in various environments.

[0072] D. Comfort: Waterproof and breathable membranes are usually soft, thin, and conform to the body, making them more comfortable and fit the sponge fabric of shoes, bags, and other items.

[0073] E. Environmental friendliness: Waterproof and breathable membranes are usually made of environmentally friendly materials, which do not produce harmful substances and have no negative impact on the environment and human health.

[0074] In addition, the waterproof and breathable membrane also uses nanotechnology, and its thickness is generally between 10μm and 25μm.

[0075] Preferably, the waterproof and breathable membrane is adhered to the top of the midsole at the location through which the breathable holes penetrate.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] The one-piece molded, waterproof and breathable seven-color rainbow foam sole of this 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 located in the center of the bottom cover 11, and an aluminum mold 121 is located in the center of the middle plate 12. The lower mold 111 includes a forefoot area 1, a midfoot area 2, and a heel area 3. The forefoot area 1 and the midfoot area 2 are separated by a first dividing piece 4; the midfoot 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 and the second partition 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; the first section 1001, the second section 1002, the third section 1003, the fourth section 1005, the fifth section 1006 and the sixth section 1007 are provided with multiple vertical columns 100.

[0081] 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.

[0082] 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.

[0083] Preferably, the diameter of the vertical column 100 is less than or equal to 1 mm.

[0084] Preferably, the diameter of the vertical column 100 is 0.2 mm to 0.8 mm.

[0085] Preferably, the height of the vertical column 100 is less than or equal to 20 mm.

[0086] Preferably, the height of the vertical column 100 is 7 mm to 14 mm.

[0087] Preferably, the height of the vertical column 100 is 10 mm.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] 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.

[0093] 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.

[0094] In existing technology, molds for two-tone foam soles do not require segmentation pieces or vertical columns 100, therefore they can be manufactured using conventional sand casting molding processes. The function of the vertical columns 100 is to form ventilation holes 1000.

[0095] 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.

[0096] 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.

[0097] The requirements for molds for multi-color foam soles differ from those for two-color foam soles. Molds for making multi-color foam soles need to be divided into different color areas, and these areas need to be separated by dividing pieces (i.e., first dividing piece 4, second dividing piece 5, third dividing piece 6, fourth dividing piece 7, fifth dividing piece 8, and sixth dividing piece 9). The material and process requirements in conventional sand casting molding processes do not meet the standard requirements for dividing pieces.

[0098] Furthermore, the mold for manufacturing the one-piece molded rainbow foam sole with waterproof and breathable functions described in this invention requires the inclusion of vertical columns 100 to form the ventilation holes 1000. The diameter of the vertical columns 100 needs to be very thin, and the rigidity of the vertical columns 100 needs to be very high to ensure that the foam sole can be perforated smoothly during the molding process.

[0099] The basic standard thickness of the segmented pieces in the molds for making multi-colored foam soles is approximately 0.4 mm to 1.2 mm, and the height can be 7 to 14 mm, with some soles even reaching 20 mm, depending on the requirements. Conventional sand casting mold processes cannot achieve this precision, and the metal materials used in conventional molds lack the necessary hardness. Due to insufficient hardness, these segmented pieces are bent or broken under mold pressure during the heating and pressing process, making it impossible to produce multi-colored foam soles. If seven colors of raw materials are used for foaming, the bending or breaking of the segmented pieces leads to a color mixing effect, failing to address the issues of cleanliness, high quality, and high comfort required by this application.

[0100] Traditional sand casting molds cannot meet the standards and requirements described in this application. On the one hand, the metal materials used in traditional molds are mostly aluminum and iron, and the hardness of these materials is not up to the standards and requirements for pressure and temperature in shoe sole molding. On the other hand, traditional mold sand casting process cannot produce a columnar mold effect, which means it cannot achieve the effect of perforation in shoe soles.

[0101] To address the aforementioned issues, the mold used in the foaming process of the one-piece molded seven-color rainbow foam sole with waterproof and breathable functions described in this invention is a 3D precision-carved mold made using a 3D printing selective laser sintering device.

[0102] 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.

[0103] like Figure 4As 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.

[0104] 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.

[0105] 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.

[0106] Preferably, the powder spreading system 74 is a roller that can roll left and right inside the forming cavity 71.

[0107] Preferably, the substrate 79 and the 3D engraving mold 81 are surrounded by loose metal powder 80.

[0108] Preferably, there are two powder feeding systems 73, which are symmetrically distributed on the left and right sides of the piston 78.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] This invention also provides a molding process for a one-piece, waterproof and breathable 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, middle plate 12 and top cover 13. Separate the semi-foamed insole 108 from the aluminum mold 121. After removing the middle plate 12, reassemble the top cover 13 and bottom cover 11 tightly. Then, within a predetermined second time (about 450 seconds), apply a predetermined second pressure (100-140 kg) and a predetermined second temperature (between 165 degrees and 185 degrees) to the assembled top cover 13 and bottom cover 11, so that 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) are fully foamed and then demolded. S4. Make an oval pattern according to the position and size of the ventilation holes, and then cut out a waterproof and breathable membrane of the same size according to the size of the pattern. Then, glue the edge of the oval waterproof and breathable membrane to the top of the midsole of the shoe sole after demolding by means of adhesive, and finally form the one-piece molded seven-color rainbow foam shoe sole with waterproof and breathable function.

[0114] 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 1, middle area 2, heel area 3 of the shoe sole in the lower mold 111, as well as the aluminum mold 121, the first dividing piece 4, the second dividing piece 5, the third dividing piece 6, the fourth dividing piece 7, the fifth dividing piece 8, the sixth dividing piece 9, and the wall surface of the vertical column 100.

[0115] Preferably, the predetermined first time is 30 seconds.

[0116] Preferably, the predetermined first temperature is between 175°C and 177°C.

[0117] The molding process proposed in this invention is one-piece foam molding, rather than creating a one-piece waterproof and breathable seven-color rainbow foam sole by combining outsole components and spraying outsole components.

[0118] 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.

[0119] The one-piece molded, waterproof and breathable seven-color rainbow foam sole is also made in one piece, rather than achieving the seven-color effect through other methods such as spraying, electroplating, or printing.

[0120] The one-piece molded, waterproof and breathable 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, making it easy for ordinary workers to operate. If it is a spraying, printing or other process, then professional technicians and professional equipment are required to operate.

[0121] 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.

[0122] The one-piece molded, waterproof and breathable 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.

[0123] 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.

[0124] The one-piece molded, waterproof and breathable seven-color rainbow foam sole described in this invention is determined by two properties: the molding process (3D printing) of the sole mold and the molding material (synthetic metal powder) of the mold. The waterproof and breathable function of this sole is also based on these two properties; the pressure from the sole and the ball of the foot enables the sole to release air.

[0125] The one-piece molded, waterproof and breathable seven-color rainbow foam sole of this invention is made in one piece because of 3D printing technology. Only a one-piece mold, including perforated mold components, can be printed, which cannot be achieved by conventional sand casting processes. Because the mold itself is made of metal alloy powder, it can be 3D printed with extreme precision and hardness, reaching the millimeter and micrometer level. The addition of perforated, breathable, and waterproof functions makes the sole of this invention even more unique.

[0126] 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 with waterproof and breathable functions, characterized in that, The one-piece molded, waterproof and breathable 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 color 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. There is a first interval between the regions; there is a second interval between the second and third color regions; there is a third interval between the third and fourth color regions; there is a fourth interval between the fourth and fifth color regions; there is a fifth interval between the fifth and sixth color regions; there is a sixth interval between the sixth and seventh color regions; and there are ventilation holes extending from bottom to top in the first, second, third, fifth, sixth, and seventh color regions, which penetrate from bottom to top through the first, second, third, fifth, sixth, and seventh color regions and the midsole.

2. The one-piece molded seven-color rainbow foam sole with waterproof and breathable function according to claim 1, characterized in that, The diameter of the vent hole is 1 mm.

3. The one-piece molded seven-color rainbow foam sole with waterproof and breathable function according to claim 1, characterized in that, The height of the vent hole is less than or equal to 20 mm.

4. The one-piece molded seven-color rainbow foam sole with waterproof and breathable function according to claim 1, characterized in that, The top of the midsole is fitted with a waterproof and breathable membrane.

5. The one-piece molded seven-color rainbow foam sole with waterproof and breathable function according to claim 4, characterized in that, The waterproof and breathable membrane is attached to the top of the midsole at the location through which the breathable holes pass.

6. The one-piece molded seven-color rainbow foam sole with waterproof and breathable function according to claim 4, characterized in that, The waterproof and breathable membrane is made of polymer materials.

7. The one-piece molded seven-color rainbow foam sole with waterproof and breathable function according to claim 6, characterized in that, The polymeric materials mentioned include polypropylene, polyethylene, polyvinyl chloride, or polytetrafluoroethylene.

8. The one-piece molded seven-color rainbow foam sole with waterproof and breathable function according to claim 4, characterized in that, The thickness of the waterproof and breathable membrane is between 10 μm and 25 μm.

9. The one-piece molded seven-color rainbow foam sole with waterproof and breathable function according to claim 1, characterized in that, The colors of the first, second, third, fourth, fifth, sixth, and seventh color regions are all different.

10. The one-piece molded seven-color rainbow foam sole with waterproof and breathable function 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.

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