Seam-free sole

Abstract

The utility model discloses a seamless sole which comprises a wear-resistant layer and a foaming layer, a non-woven fabric layer is embedded in the wear-resistant layer, required patterns can be printed on the non-woven fabric layer, a TPU (thermoplastic polyurethane) membrane paper layer is further arranged between the wear-resistant layer and the foaming layer, and the wear-resistant layer and the foaming layer are integrally connected through high-temperature fusion of TPU membrane paper. The TPU film paper layer completely wraps the outer edge of the foaming layer, so that the outer edge face of the foaming layer is flat and smooth, the overall stability of the wear-resisting layer is enhanced, meanwhile, the sole has diversified choices, and the pattern of the sole is enriched.

Description

Technical Field

[0001] This utility model relates to the field of shoe material technology, specifically to a seamless shoe sole. Background Technology

[0002] During the production process of existing shoe soles, because the upper foam layer is made of foam, some air bubbles inevitably appear on its surface, making it uneven and affecting the appearance of the entire sole. Some small holes can be repaired through reprocessing, but this is labor-intensive and time-consuming. However, if there are many more and more obvious air bubbles, the entire sole must be scrapped and remade. Utility Model Content

[0003] The purpose of this invention is to provide a seamless shoe sole to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a seamless shoe sole, comprising a wear-resistant layer, wherein a non-woven fabric layer is embedded in the wear-resistant layer, and a desired pattern can be printed on the non-woven fabric layer; a TPU film paper layer is also provided between the wear-resistant layer and the foam layer, and the three are fused together into one piece by high temperature.

[0005] As a preferred technical solution of this utility model: the TPU film layer 33 completely wraps the outer edge of the foam layer.

[0006] As a preferred technical solution of this utility model: adhesive is also sprayed between the wear-resistant layer and the TPU film.

[0007] As a preferred technical solution of this utility model, the wear-resistant layer is a transparent material.

[0008] As a preferred technical solution of this utility model, the wear-resistant layer is a high-density polyurethane material.

[0009] This application also includes an apparatus for manufacturing seamless shoe soles.

[0010] The beneficial effects of this utility model by adopting the above technical solution are: 1) The TPU film can effectively integrate the contact surface of the wear-resistant layer and the foam layer, strengthening the stability of their connection. At the same time, the TPU film wrapped around the outer edge of the foam layer makes the outer edge of the foam layer smooth and flat, avoiding air bubbles; 2) The non-woven fabric layer that can be drawn with various patterns is embedded in the wear-resistant layer, which not only strengthens the overall stability of the wear-resistant layer, but also provides a variety of patterns, enriching the style of the shoe sole.

[0011] In addition to the purposes, features, and advantages described above, this application has other purposes, features, and advantages. A further detailed description of this application will be provided below with reference to the figures. Attached Figure Description

[0012] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. In the drawings:

[0013] Figure 1 This is a schematic diagram of the wear-resistant layer mold in the manufacturing method of the seamless shoe sole of this utility model;

[0014] Figure 2 This is a schematic diagram of the molding mold in the manufacturing method of the seamless shoe sole of this utility model;

[0015] Figure 3 This is a three-dimensional structural diagram of the seamless shoe sole of this utility model;

[0016] Figure 4 This is a schematic diagram of the cross-sectional structure of the seamless shoe sole of this utility model;

[0017] Explanation of reference numerals in the attached drawings: 10, abrasion-resistant layer mold; 20, molding mold; 30, sole; 11, bottom mold; 12, top cover; 21, abrasion-resistant layer bottom mold; 22, mold cavity; 23, pressure plate; 24, upper mold; 111, stitch; 121, buckle; 211, vacuum hole; 212, air nozzle; 31, abrasion-resistant layer; 32, non-woven fabric layer; 33, TPU film paper layer; 34, foam layer. Detailed Implementation

[0018] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0019] like Figure 3 , Figure 4 As shown, this utility model discloses a seamless shoe sole. The shoe sole 30 includes an abrasion-resistant layer 31, in which a non-woven fabric layer 32 is embedded. The non-woven fabric layer 32 can be printed with the desired pattern. The abrasion-resistant layer 31 is made of transparent material. A TPU film layer 33 is also provided between the abrasion-resistant layer 31 and the foam layer 34. The TPU film layer 33 completely wraps the outer edge of the foam layer 34. The abrasion-resistant layer 31, the foam layer 34, and the TPU film layer 33 are fused together into one piece at high temperature.

[0020] Material selection for wear-resistant layer 31: High-density polyurethane raw material is mixed with catalysts (foaming agent and hardener) to adjust the viscosity, hardness, and cooling cycle of the high-density polyurethane raw material, so that the wear-resistant layer 31 can be formed better. Since polyurethane material itself has a certain shrinkage ratio, high-density polyurethane generally has a shrinkage ratio of about 0.3%, and low-density polyurethane has a shrinkage ratio of about 0.7%. Therefore, in mold making, the size of the mold is slightly adjusted according to its shrinkage ratio so that the size of the formed wear-resistant layer 31 is closer to the required standard size.

[0021] like Figure 1 As shown, the bottom mold 11 of the wear-resistant layer mold 10 has anti-slip textures, and the anti-slip textures also have needles 111, which facilitates the pre-reservation of air holes in the wear-resistant layer 31. The front end of the mold is slightly deeper and the rear end is slightly shallower. When the mold is closed, the upper cover 12 pushes the mold from front to back (due to the adjustment of the cooling cycle of the polyurethane solution, there is enough time to push the mold closed), so as to better expel the gas in the polyurethane solution (similar to the film application process). Because the gas in the polyurethane solution is fully expelled, this method can make the wear-resistant layer 31 thinner, thus making the entire sole lighter. The upper cover 12 of the wear-resistant layer mold 10 has protrusions that match the shape of the bottom mold 11. The protrusions have textures that are concave and convex mirrors the anti-slip textures on the bottom mold 11.

[0022] Furthermore, to enhance the stability of the wear-resistant layer 31, increase the edge height of the wear-resistant layer 31, reduce its shrinkage ratio, and provide a variety of patterns on the wear-resistant layer 31, a transparent material is used for the wear-resistant layer 31. A non-woven fabric layer 32 is placed on the upper cover 12. Various patterns can be printed on the non-woven fabric. The non-woven fabric is fixed to the upper cover 12. A transparent high-density polyurethane solution is poured into the bottom mold 11. After the upper cover 12 is placed on top, the non-woven fabric layer 32 is immersed in the high-density polyurethane solution. The protrusions on the upper cover 12 and their textures further ensure that the non-woven fabric layer 32 is completely immersed in the wear-resistant layer 31. The sides of the protrusions on the upper cover 12 are also provided with raised grinding edges. The non-woven fabric layer 32 located at the edge of the upper cover 12... 2. When the cover 12 is closed, the non-woven fabric layer 32 is embedded in the high-density polyurethane solution by edge grinding and extrusion. This ensures that the non-woven fabric layer 32 is fully immersed in the formed wear-resistant layer. The embedding of the non-woven fabric layer 32 not only acts as a reinforcing rib, enhancing the stability of the wear-resistant layer 31, but also ensures that when the wear-resistant layer 31 is sprayed with adhesive, the adhesive is applied to the high-density polyurethane material, facilitating subsequent fusion with the TPU film 33. At the same time, the wear-resistant layer 31 is integrally formed, and the side end face of the formed polyurethane material is flat, requiring no trimming. Only the excess non-woven fabric layer 32 needs to be trimmed, ensuring the flatness of the upper side end face of the wear-resistant layer 31. This further ensures the flatness of the joint surface after the wear-resistant layer 31 and the foam layer 34 are fused and connected.

[0023] like Figure 2As shown, the shoe sole forming mold 20 includes an abrasion-resistant layer bottom mold 21 that matches the abrasion-resistant layer 31, a foaming layer mold cavity 22 that matches the foaming layer 34, a pressure plate 23, and an upper mold 24. The abrasion-resistant layer bottom mold 21 has several vacuum holes 211 corresponding to the air pores of the abrasion-resistant layer, and connected vacuum nozzles 212. The vacuum nozzles 212 are selectively connected to an external vacuum device, and a switching valve is installed on the vacuum nozzles 212. The abrasion-resistant layer bottom mold 21, the foaming layer mold cavity 22, and the pressure plate 23 are sequentially sealed and fastened together.

[0024] The air-dried wear-resistant layer 31, with its upper surface coated with adhesive, is laid flat on the wear-resistant layer bottom mold 21, ensuring a tight fit between the bottom mold 21 and the wear-resistant layer 31. A TPU film layer 33 is then placed over the mold, and the TPU film layer 33 is sealed and fixed to the upper surface of the mold using the pressure plate 23. A vacuum cleaner is connected to an air nozzle, and by drawing a vacuum at the bottom of the mold, the TPU film layer 33 is tightly adhered to the wear-resistant layer 31 and the periphery of the foam layer mold cavity 22. The valve is closed, and a low-density polyurethane solution is poured in. The upper mold 24 is then placed on top. The high temperature and pressure generated by the foaming of the urethane solution cause the TPU film layer 33 to fuse with the wear-resistant layer 31, adhesive and foam layer 34 at high temperature, realizing the fusion of the wear-resistant layer 31 and the foam layer. At the same time, the TPU film layer 33 is coated on the side of the foam layer. The TPU film itself is smooth and flat, which makes the outer edge of the foam layer 34 smooth and flat, effectively improving the aesthetics of the sole and increasing the yield of the product. There is no need to repair the air bubbles generated on the outer edge of the foam layer 34 during foaming, saving time and labor.

[0025] Typically, foamed materials generate a lot of heat during the foaming process. At the same time, since the foamed material is in the closed cavity of the mold, high pressure is also generated, which can generally reach 10 atmospheres. Through high pressure and high temperature, the TPU film and paper are fused together, resulting in a flat and smooth surface with a tight fusion.

[0026] In summary, this application proposes a method for manufacturing a seamless shoe sole, comprising the following steps;

[0027] S1: Making a wear-resistant layer with pores: Pour a high-density polyurethane mixture containing a catalyst into the bottom mold of the wear-resistant layer mold, cover it with the top cover, and extrude it to obtain a wear-resistant layer with an internal non-woven fabric layer and pores on the surface; spray glue on the upper surface of the wear-resistant layer and let it air dry.

[0028] S2: Provide a molding die, which includes a wear-resistant layer bottom mold for accommodating the wear-resistant layer and a mold cavity for molding the foam layer, wherein the wear-resistant layer bottom mold is provided with vacuum holes corresponding to the air holes of the wear-resistant layer and connected to vacuum nozzles;

[0029] S3: The wear-resistant layer made in S1 is laid on the wear-resistant layer bottom mold of the molding die, so that the air holes of the wear-resistant layer are aligned with the vacuum air holes;

[0030] S4: Cover the mold cavity with a TPU film paper layer, and seal and fix the periphery of the TPU film paper layer by a pressure plate;

[0031] S5: Vacuum is drawn through the vacuum nozzle to make the TPU film paper layer adhere tightly to the surface of the wear-resistant layer and the side wall of the mold cavity;

[0032] S6: Inject low-density polyurethane foam into the cavity formed by the TPU film layer;

[0033] S7: Cover with the upper mold and heat it to make the low-density polyurethane raw liquid foam. The high temperature and pressure generated by foaming cause the TPU film paper layer, wear-resistant layer and foam layer to fuse together.

[0034] S8: Trim off the excess TPU film paper from the edge of the sole to form a seamless, one-piece sole.

[0035] As a preferred technical solution of this application, the upper cover 12 of the wear-resistant layer mold 10 is provided with buckles 121 for fixing non-woven fabric at its edge. The non-woven fabric is fixed on the buckles 121. After the high-density polyurethane mixture is injected into the bottom mold, the upper cover 12 is closed, and the non-woven fabric layer 32 is immersed in the high-density polyurethane mixture. The non-woven fabric on the side wall is also provided with raised grinding edges on the side of the protrusion of the upper cover 21. The grinding edges squeeze the non-woven fabric layer to make it embed into the high-density polyurethane solution, thus ensuring that the non-woven fabric layer is fully immersed in the formed wear-resistant layer. The upper surface of the bottom mold is designed with holes corresponding to the buckles 121.

[0036] As a preferred technical solution of this application, the front end of the bottom mold is slightly deeper and the rear end is slightly shallower. When the mold is closed, the upper cover 12 pushes the mold from front to back (because the cooling cycle of the polyurethane solution is adjusted, there is enough time to push the mold closed) so as to better discharge the gas in the polyurethane solution (similar to the film application process).

[0037] The following is a brief description of the manufacturing process and principle of the seamless shoe sole of this utility model.

[0038] Wear-resistant layer production

[0039] Material configuration: High-density polyurethane raw material is mixed with catalyst (foaming agent, hardener) to adjust viscosity, hardness and cooling time.

[0040] Preferably, the mixture of high-density polyurethane raw material and catalyst (foaming agent, hardener) is a transparent material.

[0041] Mold design: The bottom mold is equipped with pins (for forming air holes), side guards and anti-slip textures, and the top cover is equipped with buckles to fix the non-woven fabric and protrusions. The protrusions are set with textures that mirror the anti-slip textures. The front end of the mold is deep and the rear end is shallow. When closing the cover, it is pushed from front to back to fully expel the gas. Shrinkage ratio compensation: The mold size is finely adjusted according to the shrinkage ratio of polyurethane (3 / 1000 for high density and 7 / 1000 for low density).

[0042] Non-woven fabric integration: After the non-woven fabric is printed with a pattern, it is fixed to the top cover. When the mold is closed, it is immersed in polyurethane liquid. After molding, it is located inside the wear-resistant layer. Only the inner edge of the non-woven fabric layer needs to be trimmed, which ensures the flatness of the upper surface of the side wall of the wear-resistant layer.

[0043] This application also includes equipment for manufacturing seamless shoe soles.

[0044] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A seamless shoe sole, characterized in that: It includes a wear-resistant layer (31) and a foam layer (34). A non-woven fabric layer (32) is embedded in the wear-resistant layer (31). The non-woven fabric layer (32) can be printed with the required pattern. A TPU film paper layer (33) is also provided between the wear-resistant layer (31) and the foam layer (34). The wear-resistant layer (31) and the foam layer (34) are connected by high temperature fusion of the TPU film paper. The TPU film paper layer (33) completely wraps the outer edge of the foam layer (34).

2. The seamless shoe sole according to claim 1, characterized in that: The upper surface of the wear-resistant layer (31) is also coated with adhesive.

3. The seamless shoe sole according to claim 1, characterized in that: The wear-resistant layer (31) is a transparent material.

4. The seamless shoe sole according to claim 1, characterized in that: The wear-resistant layer (31) is made of high-density polyurethane material.

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