Methods and apparatus for manufacturing particulate foam components from foam particles for sportswear, sports equipment, or balls; methods for calibrating processes for manufacturing particulate foam components from foam particles for sportswear, sports equipment, or balls; particulate foam components from foam particles for sportswear, sports equipment, or balls; and shoes.

Abstract

Using electromagnetic waves to remove foam particles from sportswear, sports equipment, or balls. To provide a method for manufacturing particle foam components. [Solution] This method involves the steps of filling the mold cavity and welding the foam particles together. The process includes the steps of heating the foamed particles with electromagnetic waves and demolding the foamed particles. The system monitors parameters characteristic of electromagnetic wave absorption, and when these parameters change by a predetermined amount... In this case, the heating of the foam particles is terminated. This method ensures that the correct amount of heat is applied to the foam particles. It is supplied by a simple method.

Description

Technical Field

[0001] The present invention relates to a method and apparatus for manufacturing particle foam parts from foam particles for sports clothing, sports equipment, or balls, a method for calibrating a process for manufacturing particle foam parts from foam particles for sports clothing, sports equipment, or balls, particle foam parts from foam particles for sports clothing, sports equipment, or balls, and shoes.

Background Art

[0002] WO 2013 / 05081 discloses a method for manufacturing particle foam parts, in which a mixture of foam particles and a dielectric transfer liquid is heated by electromagnetic waves to melt the foam particles to form particle foam parts. As the electromagnetic waves, radio waves or microwaves are used. The material of the foam particles is formed from polypropylene (PP).

[0003] U.S. Patent No. 3,060,513 discloses a method for sintering moistened thermoplastic foam particles. The particles are dielectrically heated and simultaneously compressed in a mold. The electromagnetic waves are applied at a frequency of about 2 to 1000 MHz.

[0004] A similar method is described in U.S. Patent No. 3,242,238, in which the foam particles are moistened with an aqueous solution and exposed to an electromagnetic field at a frequency of about 5 to 100 MHz.

[0005] British Patent No. 1,403,326 describes a method for welding foamed polystyrene foam particles, in which the particles are moistened with an aqueous solution and exposed to an electromagnetic field of 5 to 2000 MHz.

[0006] ​​​​​​​​​​​ International Publication No. 01 / 64414 describes polyolefins moistened with a liquid medium. Further methods for heating polymer particles with electromagnetic waves, particularly microwaves, are disclosed. The temperature inside the molding jig is controlled by controlling the pressure present within the molding jig.

[0007] In the methods described above, in all cases, the moistened foam particles are heated by electromagnetic waves, and electromagnetic waves Energy is absorbed by the liquid and transferred to the particles.

[0008] U.S. Patent No. 5,128,073 describes a material that absorbs high-frequency energy and is coated with Disclosed are thermoplastic particles that can be heated by electromagnetic waves. The coating emits electromagnetic energy, which is then released onto the foam particles. Electromagnetic waves in the range of 40MHz to 2450MHz are used to weld the components together.

[0009] These methods have been known for decades. Nevertheless, these methods are actually This has not been successful. There are several reasons for this. In laboratory samples, these methods It works very well.

[0010] Therefore, in fact, foamed particles are, for example, in the pamphlet International Publication No. 2014 / 128214. As is known from Lett, welding is almost without exception performed by saturated dry steam. Compared to welding by hand, electromagnetic wave welding has considerable advantages in principle, but electromagnetic wave welding However, this has not actually been successful in recent decades. In the case of electromagnetic waves, the energy is more targeted. Because it can be transmitted directly, there is no need to heat the auxiliary object. When using steam, first steam Steam must be generated in the generator. Then, the steam is supplied to the jig via the pipeline. It must be. All of these parts must be sufficiently designed so that steam does not condense inside the parts. It must be heated to a high temperature. This results in considerable heat loss. In addition, grain In equipment for manufacturing foamed components, the most common components are steam generators and steam pipelines. It occupies installation space. If steam is not required for the welding of foam particles, the entire device can be much It will be possible to form it compactly.

[0011] For the applicant of this patent application, the transition to industrial production was only very recently successful. The applicant first stated that attempts to weld foam particles with electromagnetic waves had not been successful for several decades. The reason for this was recognized as the inability to uniformly introduce heat into the foam particles. As a result, uniform welding of the particle foam components cannot be achieved.

[0012] International Publication No. 2017 / 125410, International Publication No. 2017 / 12541 Pamphlet No. 2, International Publication No. 2018 / 100154, International Publication No. 20 Pamphlet No. 21 / 073924, and International Publication Pamphlet No. 2022 / 229030 Lett has developed a method for manufacturing particle foam components that provide a uniform heat distribution within the mold space. The device is disclosed.

[0013] In particular, International Publication No. 2018 / 100154 describes the manufacturing of particle foam components. An apparatus for which a molding jig is provided for defining the boundary of the molding space, and which comprises at least two concrete The capacitor plates are positioned adjacent to the molding space, and these capacitor plates are for electromagnetic radiation connected to a radiation source and designed such that the radiation source for electromagnetic radiation emits electromagnetic radiation, discloses a device. This device is provided with a voltage measurement device that can measure the voltage applied to a capacitor. This voltage measurement device is used to adjust an oscillation circuit designed using an electromagnetic wave generator, and thus to adjust the power supplied to the capacitor.

[0014] The present invention is based on the object of providing a method and a device for manufacturing particle foam parts from foam particles for sports clothing, sports equipment, or balls, and a method for calibrating a process for manufacturing particle foam parts from foam particles for sports clothing, sports equipment, or balls, whereby it becomes possible to reliably industrially produce particle foam parts from foam particles for sports clothing, sports equipment, or balls and shoes, and high-quality particle foam parts can be obtained from foam particles for sports clothing, sports equipment, or balls. by welding the foam particles using electromagnetic waves,

Prior Art Documents

Patent Documents

[0015]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Patent Document 5

Patent Document 6

Patent Document 7

[0016] This objective is achieved by the subject matter of the independent claim. Advantageous embodiments are described in their respective dependent claims. It is clearly stated in the claim.

[0017] According to a first aspect, the present invention relates to foam for sportswear, sports equipment, or balls. A method for manufacturing particle foam components from particles, in particular, A step of filling the molding space, The steps include heating and welding foam particles with electromagnetic waves, The demolding step, Regarding methods including

[0018] This method monitors parameters characteristic of electromagnetic wave absorption during heating of foam particles, and this parameter The heating of the foam particles is terminated when the meter changes by a predetermined amount.

[0019] This invention relates to a mechanism in which the absorption capacity of a material rapidly improves as the material of the foamed particles being welded melts. This is based on the understanding that polar molecules and polar functional groups are excited and vibrate by electromagnetic waves. It has long been known that by doing so, electromagnetic waves are absorbed. Because the bonds between them are broken, individual molecules or their functional groups can move more easily. For example, PEEK, which has polar functional groups but is firmly incorporated into the molecular structure. In materials where polar functional groups are present, they cannot move, and the material absorbs very little electromagnetic radiation. Therefore, in order to absorb electromagnetic waves, the polar functional groups must be movable so that they can vibrate. This is necessary. If the mobility of polar functional groups is very high, friction will not occur or Because it causes only slight friction, only a small amount of electromagnetic waves can be absorbed. Therefore, each material Generally, there is a peak region in which the material can absorb electromagnetic waves well. The mobility of the functional group is Because it is temperature-dependent, the ability to absorb electromagnetic waves is also generally temperature-dependent.

[0020] Furthermore, the inventors of this invention have developed foam particles for sportswear, sports equipment, or balls. The problem with welding materials using electromagnetic waves is that the heat must be distributed uniformly within the molding space. Furthermore, I realized that it was necessary to measure it accurately. The foaming particles were vaporized. When welding, if the welding is insufficient, all areas of the particle foam component will be sufficiently welded. Steam can be supplied for a relatively long time. However, the steam temperature is limited. Overheating can never occur. This is because the welding of foam particles by electromagnetic waves is different from welding by steam. In comparison, this is one reason why it has not been successful in the past.

[0021] Therefore, once the materials to be welded have melted, the heat supply is interrupted during electromagnetic welding. It should be done. When the foam particles melt, they combine during cooling to form foamed particle components, and this This is called welding. Further heating could cause the material to heat up to a relatively high temperature and burn. Therefore, it is not necessary, but rather harmful.

[0022] According to the present invention, the material's ability to absorb electromagnetic waves changes during melting, and this change is generally By taking advantage of the fact that it happens rapidly, the heating time can be adjusted. As a result, the precision of the heat supplied can be controlled. Precise weighing is achieved in a very simple way, resulting in good welding and preventing material burning. This will be reliably prevented.

[0023] Sportswear, sports equipment, or sports equipment that are welded together by a method of forming particulate foam components. The foamed particles for the ball are preferably foamed particles made from a thermoplastic material. The materials include, in particular, foamed polyurethane (ePU) and polyether block amide (PEBA). ) or foamed polyethylene (ePE) may be used. These are polar materials that absorb electromagnetic waves. It is a plastic, and during melting, it exhibits a very strong change in its ability to absorb electromagnetic waves.

[0024] For example, expanded polypropylene (ePP) or expanded polystyrene (ePS) as a base Foamed particles from nonpolar plastics, such as those used for foaming, can also be welded together to form foamed particle components. These materials do not have polar groups, so they absorb very little electromagnetic radiation. No. Therefore, it is convenient to add a dielectric heat transfer medium such as water. A small amount of water is sufficient for moistening. The water can be added in liquid form or as a vapor. Water molecules form dipoles, so they absorb electromagnetic waves well, and when electromagnetic waves are emitted, they rapidly... It gets hot. Even if water is added to the foaming particles in the form of steam, at least some of the water remains. It condenses on the surface of the foam particles, forming a liquid film. When water is added in liquid form, the water becomes electrically charged. The foam particles exist in liquid form before being heated by magnetic waves, and generally a film is also formed on the surface of the foam particles. When foam particles are heated with electromagnetic waves, the water is heated and evaporates. Phase transitions cause significant changes in the ability to absorb electromagnetic waves. Water is completely converted into vapor. In this case, it means that high-temperature steam suitable for welding the foam particles is present in the mold space. This means that because individual water molecules can move freely in vapor, they are more susceptible to electromagnetic waves than liquid water. Almost no absorption. Further heating is no longer necessary. The heating process can be terminated. Cut.

[0025] The foamed particles are derived from biological materials such as industrial popcorn made from corn, for example. It can also be formed, and this popcorn uses a binder that holds the popcorn together after heating. The sea urchin is provided with a binder, or coated with a binder.

[0026] In the meaning of this invention, the term "popcorn" is particularly used to refer to puffed corn (corn). In plants such as *Cyperus rotundus* and *Cyperus convar.*, the water present in the seeds evaporates rapidly. As a result, the starch contained in the seeds changes to a foamy consistency. By being converted, if applicable, rapid heating after the corresponding fat fatting occurs. This includes all materials that explode at high temperatures. These properties include, among others, quinoa grain and amaranth. Also known from sas, rice, or wheat, materials based on these base materials are also part of the present invention. In terms of meaning, it is explicitly called "popcorn," and is included in "popcorn." The term "corn" is not intended to be limited to corn only, but also to other types of corn. It was chosen for its simplicity, clarity, and readability.

[0027] The binder melts when exposed to heat and solidifies when cooled, thus forming popcorn. It can have a thermoplastic material that binds the particles together. The binder is chemically reacted when heated. It may also contain an adhesive that reacts with the target and binds the popcorn particles together.

[0028] Suitable binders include, in particular, thermoplastic resins, thermosetting resins, amino resins, and phenolic resins. Isocyanates, proteins, tannins, starch, synthetic or natural binders, or a mixture of binders, for example, urea-formaldehyde resin, melamine-formaldehyde D resin, melamine-reinforced urea-formaldehyde resin, tannin-formaldehyde resin, Phenol-formaldehyde resin, polymeriphenylmethane-diisocyanate or It is a mixture of those.

[0029] The proportion of binder in the molded part (mass %) based on the mass of the molded part is preferably <10%. Preferably, it is <5%.

[0030] Biological materials generally contain a certain amount of water. This water contained in biological materials is electromagnetic. It absorbs the waves and heats the popcorn particles and binder. When the binder evaporates, the electromagnetic waves The water absorption capacity, on the other hand, changes in the same way as explained above, and this change is used as a characteristic parameter. Therefore, it can be determined. The characteristic parameters are determined when the material is heated and bonded in the molding space. It is also an indicator of the formation of granular foam components.

[0031] Therefore, various physical mechanisms exist that cause changes in the absorption capacity of electromagnetic waves. Electromagnetic waves heat the material present in the molding space, so the strong ability to absorb electromagnetic waves changes. The transformation always indicates a reproducible stage of the heating process. Therefore, the characteristic parameters are, These are physical variables characteristic of the foam particles being applied, and they change due to electromagnetic radiation, therefore Based on the changes, a specific process state or treatment state of the foam particles to be welded can be determined. It is possible.

[0032] Subsequently, the heating process can be terminated depending on the changes in characteristic parameters. The process can be terminated immediately if the characteristic parameters change, or if the characteristics change. After the parameter changes, the heating process should be terminated within a predetermined period (heating process Delayed termination can also be advantageous. The delay period is material-specific, and the value of the delay period is based on experience. It can be determined precisely. Most polar plastics melt as a result of the action of electromagnetic waves. In the case of buck materials, it has been found that a very short delay period or a delay period of "0" is advantageous. This is especially true for other materials that form bonds between foam particles as a result of chemical reactions. In some cases, a delay period greater than 0 may be advantageous.

[0033] Electromagnetic waves can be generated by capacitors located inside the shaping space. In this case, electromagnetic waves can be applied to the capacitor with a predetermined voltage amplitude, within the molding space. The power introduced, or the first or second derivative of the power with respect to time, is used as a characteristic parameter. It can be measured by applying electromagnetic waves to a capacitor with a predetermined power, and the capacitor The voltage drop across the ends of the device, or the first or second derivative of the voltage drop with respect to time, is used as a characteristic parameter. It can also be measured as a data type.

[0034] When directly monitoring characteristic parameters, in order to determine a change of a certain amount, the characteristic parameters This checks whether the value changes by a predetermined threshold within a predetermined time interval. This refers to a rapid change in characteristic parameters.

[0035] When monitoring the first time derivative of a characteristic parameter, in order to determine the change by a certain amount, The first time derivative of the sex parameter is checked to see if it exceeds a predetermined threshold. This signifies a rapid change in characteristic parameters.

[0036] When monitoring the second time derivative of a characteristic parameter, in order to determine the change by a certain amount, 2 Here too, it is determined whether the next time derivative exceeds a predetermined threshold. This is a characteristic parameter. This means that the meter profile itself changes very strongly. When the data profile is input into the graph, the second time derivative exceeding a certain threshold represents the characteristic. This means that the curvature of the parameter profile increases over time. This shows a strong change in characteristic parameters.

[0037] Therefore, there are various methods that can detect strong changes in characteristic parameters. In order to obtain a signal that is intended to terminate the heating of the foam particles by magnetic waves, this signal It is important that the characteristics of the foam particles are characteristic and reproducible for each heating state. This is given by all the methods described above.

[0038] Preferably, the particle foam component generated in the molding space is heated and then removed from the molding space before demolding. It is cooled. This cooling process is also called stabilization.

[0039] Electromagnetic waves are preferably RF radiation. RF radiation has a frequency of 30 kHz to 300 MHz. It has several ranges. In many states, the 27.12 MHz frequency is available for industrial use. This is a suitable frequency for heating foam particles.

[0040] The magnitude of the high-frequency voltage applied to the capacitor is preferably 10 3 V~10 5 Range of V , especially 5x10 3 V~1.5×10 4 This is within the range of V.

[0041] In a further embodiment, the present invention uses electromagnetic waves to produce sportswear, sports equipment, Or a method for calibrating the process of manufacturing particle foam components from foamed particles for balls. This method involves a mold that defines a specific molding space and foam particles of a specific material type. Using one of the methods described above, sportswear, sports equipment, or Manufacture at least one particle foam component for the ball and heat the foam particles to the characteristic parameters Control or terminate based on this. Then, for sportswear, sports equipment, or balls Further particle foam components are produced during the manufacturing heating interval corresponding to the period determined in the calibration process. In either case, the foam particles are manufactured by heating them with the same settings for supplying electromagnetic waves. These settings are primarily applied power or applied voltage.

[0042] As a result, the manufacturing heating interval, which defines the period during which the foam particles are heated by electromagnetic waves, is determined by the calibration process. It will be determined in S.

[0043] The appropriate heating period for the foam particles depends on the molding jig and the material of each foam particle. Because it depends on the type, the individual manufacturing heating intervals for this can be easily and quickly determined. This allows for the easy and reliable manufacture of high-quality particle foam components.

[0044] Calibration process for multiple particle foam components for sportswear, sports equipment, or balls. It can also be manufactured in this way, and in either case, the heating period can be measured. Manufacturing time interval This is therefore determined based on multiple periods measured during the calibration process. The average or median value between these values ​​can be determined as the manufacturing time interval.

[0045] Furthermore, when determining the manufacturing time interval, the mean or median of the measured period is used. Only periods that fall within a predetermined multiple of the standard deviation can be considered.

[0046] To determine the quality factor of the manufacturing process, a statistical evaluation of the measured period is performed. Yes, it is possible. If the quality factor indicates that the stability of the manufacturing process is too low, then the manufacturing process By changing specific parameters of the product, the manufacturing process can be based on this quality factor. It can be optimized.

[0047] You can change at least one of the following parameters, then as described above. The manufacturing time interval can be determined again according to the calibration process. - Applied power of electromagnetic waves, - Applied voltage for generating electromagnetic waves, - Amount of heat transfer medium supplied to the molding space, - Amount of foam particles supplied to the molding space, - The pressure applied to the foam particles by the molding jig before the foam particles are heated.

[0048] The expert system will determine at least one parameter to be changed and the extent of the change. Therefore, it can be determined automatically.

[0049] In a further embodiment, the present invention relates to a product for sportswear, sports equipment, or balls. An apparatus for manufacturing foamed particle parts from foam particles, comprising a molding tool that defines the boundary of the molding space. The device is equipped with at least two capacitor plates positioned adjacent to the molding space, and these The capacitor plate is connected to a radiation source for electromagnetic radiation, and the radiation source for electromagnetic radiation emits electromagnetic radiation Designed to emit and to automatically perform the methods described above, Regarding devices that possess your equipment.

[0050] In a further embodiment, the present invention relates to a product manufactured according to one of the methods described above. This relates to particulate foam components made from foamed particles for sportswear, sports equipment, or balls. The foam component may be the sole or part of the sole, and especially the insole or part of the insole.

[0051] In a further aspect, the present invention relates to the above-mentioned particle foaming portion from foamed particles for sportswear. This relates to shoes, particularly athletic shoes, including soles or insoles from the product.

[0052] The present invention includes the following embodiments.

[0053] [Embodiment 1] Using electromagnetic waves to generate particles from foamed particles for sportswear, sports equipment, or balls. A method for manufacturing foam components, - A step of filling the molding space, - A step of heating and welding foam particles with electromagnetic waves, - Includes the step of demolding, During the heating of the foam particles, we monitor parameters characteristic of electromagnetic wave absorption, and when these parameters are If only a quantitative change occurs, the heating of the foamed particles is terminated. method.

[0054] [Embodiment 2] Electromagnetic waves are generated by a capacitor located inside the shaping space. Electromagnetic waves are applied to the capacitor with a predetermined voltage amplitude, and power or The first or second derivative of power with respect to time is measured as a characteristic parameter, or When electromagnetic waves are applied to a capacitor with a predetermined power, the voltage drop across the capacitor or the drop across the capacitor is... The first or second derivative of the lower voltage with respect to time is measured as a characteristic parameter. The method according to Embodiment 1, characterized in that...

[0055] [Embodiment 3] After heating and before demolding, the particle foam component is cooled within the molding space. The method according to Embodiment 1 or 2, characterized by the features described herein.

[0056] [Embodiment 4] RF radiation is used as electromagnetic waves, particularly in the frequency range of 30 kHz to 300 MHz. , The method according to any one of Embodiments 1 to 3, characterized in that

[0057] [Embodiment 5] Using electromagnetic waves to generate particles from foamed particles for sportswear, sports equipment, or balls. A method for calibrating a process for manufacturing foam components, Sportswear, sports equipment, or ball according to any one of Embodiments 1 to 4 At least one particle foam component for use in a mold that defines a specific molding space and a specific material Manufactured using Ip foam particles in a calibration process, with a period of heating by electromagnetic waves. The characteristic parameters are measured until they change by a certain threshold, and sportswear, sports The equipment, or additional particle foam components for the ball, correspond to the period determined in the calibration process. During the manufacturing heating interval, in both cases, the foam particles are added with the same settings for supplying electromagnetic waves. A method of production that involves heating.

[0058] [Embodiment 6] Multiple particle foam components for sportswear, sports equipment, or balls undergo a calibration process. The inside is manufactured according to one of the methods described in Embodiments 1 to 4, in any case heated The period is measured, and the manufacturing time interval is determined based on multiple periods measured during the calibration process. Determined The method according to Embodiment 5, characterized in that...

[0059] [Embodiment 7] The average or median of each period is determined as the manufacturing time interval. The method according to Embodiment 6, characterized in that...

[0060] [Embodiment 8] A period that falls within a predetermined multiple of the standard deviation centered on the mean or median of the measured period. Only this is considered when determining the manufacturing time interval. The method according to embodiment 6 or 7, characterized in that...

[0061] [Embodiment 9] A statistical evaluation of the measured period is performed to determine the quality factor of the manufacturing process. , The method according to any one of embodiments 6 to 8, characterized in that

[0062] [Embodiment 10] If the quality factor indicates that the stability of the manufacturing process is too low, then at least the manufacturing process By changing one specific parameter, the manufacturing process can be modified based on the quality factor. Optimized The method according to Embodiment 9, characterized by the features described herein.

[0063] [Embodiment 11] The following parameters, - Applied power of electromagnetic waves, - Applied voltage for generating electromagnetic waves, - Amount of heat transfer medium supplied to the molding space, - Amount of foam particles supplied to the molding space, - The pressure applied to the foam particles by the molding jig before the foam particles are heated, Modify at least one of the following, and then the method described in any one of Embodiments 1 to 4 To manufacture multi-particle foam components for sportswear, sports equipment, or balls in accordance with the law. This determines the manufacturing time interval again. The method according to Embodiment 10, characterized by the features described herein.

[0064] [Embodiment 12] The expert system determines at least one parameter to be changed and the extent of the change. It is automatically determined. The method according to Embodiment 11, characterized by the features described herein.

[0065] [Embodiment 13] Manufacturing particulate foam components from foam particles for sportswear, sports equipment, or balls. A device for that purpose, A molding jig for defining the boundary of a molding space, comprising at least two capacitor plates It is positioned adjacent to the shape space, and the capacitor plate is connected to a radiation source for electromagnetic radiation, A molding jig designed to emit electromagnetic radiation from its radiation source. Equipped with, Designed to automatically perform the method described in any one of Embodiments 1 to 12 Having a control device, Device.

[0066] [Embodiment 14] Sportswear, etc., manufactured according to the method described in any one of Embodiments 1 to 4 Particle foam components made from foamed particles for sports equipment or balls.

[0067] [Embodiment 15] Embodiments in which the particle foam component is the sole or part of the sole, particularly the insole or part of the insole Particle foam components as described in 1 to 14.

[0068] [Embodiment 16] A shoe, particularly an athletic shoe, including a sole or insole according to the above-described embodiment.

[0069] Possible embodiments of the present invention will be further described below with reference to the following drawings. [Brief explanation of the drawing]

[0070] [Figure 1] This figure shows an exemplary embodiment of an apparatus for manufacturing particulate foam components from foam particles for sportswear, sports equipment, or balls. [Figure 2a] This is a cross-sectional view of a molding jig in a partially open position. [Figure 2b] This is a cross-sectional view of a molding jig in a partially closed position. [Figure 3] This is an electrical circuit diagram showing a generator for electromagnetic radiation that forms an adjustable oscillation circuit, and a molding jig. [Figure 4] This is a circuit diagram showing a control device for controlling the power supply. [Modes for carrying out the invention]

[0071] Possible embodiments of various aspects of the present invention mainly relate to sports footwear such as shoes and soles. The present invention relates to a method and apparatus for manufacturing particulate foam components from foamed particles for sportswear, including sports apparel. This is described in the following detailed description. However, the present invention is not limited to these embodiments. I would like to emphasize that this is not the case. Rather, this invention is for various types of sportswear, sports Not only articles, but also each of the sports equipment and sports goods, or at least one The component can be used in balls containing particle foam components, for example, any type of ball. , or rackets such as tennis rackets, golf clubs, baseball bats, badminton rackets racquets, cricket bats, ice hockey sticks, hockey sticks , squash rackets, table tennis rackets, or shin guards used in sports, It can be used in any type of protective clothing, such as knee pads or elbow pads.

[0072] Manufacturing particulate foam components from foam particles for sportswear, sports equipment, or balls. The basic structure of apparatus 1 is shown in Figure 1. Apparatus 1 consists of a material container 2, a molding jig 3, and material It includes a conduit 4 connecting the container 2 to the molding jig 3. The granular foam component is manufactured from foamed particles. It is used in sportswear, sports equipment, or balls.

[0073] Material container 2 serves to contain the loose foam particles. Material container 2 has a bottom 5. Furthermore, in the bottom region, it is connected to a compressed air source 7 via a compressed air pipeline 6. Compressed air The conduit 6 is connected to a plurality of nozzles (not shown) located at the bottom 5, thereby Multiple airflows (=fluidized air) can be introduced into the material container 2, and these airflows can be used to supply the material container The foam particles present in container 2 are swirled around, thereby separating the foam particles.

[0074] An opening is formed in the bottom region 5 of the material container 2, and the transport pipeline 4 is in contact with this opening. It is connected. The opening can be closed by a slide (not shown).

[0075] The drive nozzle 8 is located in the transport pipeline 4 adjacent to the material container. It is connected to the compressed air source 7 by a further compressed air pipeline 9. This drive nozzle 8 is supplied The supplied compressed air passes through the drive nozzle 8 into the transport pipeline 4 and flows towards the molding jig 3. Therefore, it functions as driving air. As a result, the driving nozzle 8 on the side facing the material container 2 is negatively affected. Pressure is generated, and this negative pressure draws the foam particles out of the material container.

[0076] The transport conduit 4 opens into the filling injector 10 which is connected to the molding jig 3. The injector 10 is connected to the compressed air source 7 via a further compressed air pipeline 11. The compressed air supplied to the filling injector 10 is used, on the one hand, to fill the molding jig 3. It is used, and compressed air is used to direct the flow of foam particles in the direction of the molding jig 3. On the other hand, The compressed air supplied to the filling injector 10 is released when the filling operation into the molding jig 3 is completed. Additionally, it can be used to blow foam particles back into the material container 2 from the transport pipeline 4. .

[0077] The molding jig 3 is formed from two mold halves 12 and 13. At least one molding space 14 through which the filling injector 10 opens is two mold halves A boundary is defined between them. By moving the two mold halves 12 and 13 together... This reduces the volume of the molding space 14. Move the mold halves 12 and 13 apart. When this is done, a gap called a crack gap is formed between the mold halves 12 and 13. This type of forming jig 3 is also called a crack gap forming jig.

[0078] This apparatus 1 includes, as is typical in conventional apparatuses for manufacturing particle foam components. There is no steam generator or steam supply unit to the molding space 14. In the molding space 14, moisture is released into the foamed particles. It can pass through residual moisture contained in the material and moisture contained in compressed air. Meanwhile, the apparatus 1 saturated the molding space 14 with dry foam particles for additional heating or preheating. To supply drying steam and / or during transport from material container 2 to molding space 14, foaming is performed. To moisten the particles, a steam generator and steam are supplied to the molding space 14 and / or the conveying pipeline 4. It can also be formed with a supply unit. The foamed particles located in the material container 2 are liquid It can also be moistened with water, and for this purpose, a corresponding nozzle for atomizing water is provided in the material container 2 It will be placed there.

[0079] In both cases, capacitor plates 15 and 16 are positioned on mold halves 12 and 13. These capacitor plates are made of highly conductive materials such as copper or aluminum. In both cases, it is composed of the material. The filling injector 10 is positioned on the mold half 13. The filling injector 10 penetrates the recess of the capacitor plate 16, and this The recess is attached to the mold half 13.

[0080] Capacitor plates 15 and 16 generate high-frequency voltage via wires 17. It is connected to the device 18. These wires 17 are generally waveguides. This embodiment In this state, the waveguide is formed from a hollow tube having, for example, a rectangular cross-section and made of a conductive material. However, the generator 18 is connected to the capacitor plates 15 and 16. There are other types of waveguides that are more suitable, such as coaxial cables.

[0081] The mold halves 12 and 13 are made of, for example, polytetrafluoroethylene (PTFE), Polyethylene, especially UHMWPE, polyetherketone (PEEK), etc., especially electromagnetic RF It has a body that can be formed from a non-conductive material that is substantially transparent to radiation. Only the densa plates 15 and 16 are formed to be conductive. "Substantially transparent A "material" is a material that can transmit electromagnetic radiation, especially RF radiation. However, This material converts some of the electrical RF radiation into heat, and also the mold halves 12 and 13 themselves. To heat it, the target is shaped to have specific absorption characteristics for electromagnetic RF radiation. It is possible. This will be explained in more detail below.

[0082] Alternatively, one or both of the mold halves could be made of a conductive material such as aluminum or steel. If they contain a specific material, these mold halves can also form capacitor plates. However, the two mold halves are basically electrically insulated from each other. Preferably, two One half of the mold is formed to be conductive, and the other half of the mold is non-conductive. It is formed in such a way. The conductive mold half is three-dimensionally contoured on the particle foam component. The conductive mold half can be contoured in three dimensions so that a smooth surface is formed. This results in a smooth or precisely defined surface texture, and therefore, preferably, particle generation It is used to create a visible surface on foam components.

[0083] The molding jig is equipped with a negative pressure pump so that negative pressure or vacuum can be applied to the molding space 14. It can be optionally connected to 19. This negative pressure removes moisture contained in the molded space 14. It withers.

[0084] The condenser plates 15 and 16 are preferably provided with a cooling device. In one embodiment, the cooling device directs the cooling air to a condenser plate facing away from the molding space 14. It is formed by a fan 20 directed towards sides 15 and 16 to enhance cooling. Cooling fins 21 can be provided on the condenser plates 15 and 16.

[0085] Alternatively or as an addition, temperature control lines may be placed on capacitor plates 15 and 16. It is also possible to guide the temperature control medium through this temperature control conduit. For example, a liquid such as water or oil is preferably used.

[0086] Using the above device, foam particles for sportswear, sports equipment, or balls can be used. The method for manufacturing particle foam components is described below.

[0087] This method follows the following basic steps, namely: - A step of filling the molding space 14, - A step of welding foam particles, - Stabilization step (optional), - The demolding step, - A step to clean the jig (optional), Includes.

[0088] To fill the molding space 14, compressed air is supplied to the area of ​​the bottom 5 of the material container via the compressed air pipeline 6. Air is blown in, causing the foam particles present in the material container to swirl and separate. At the same time, the driving air Air is also supplied to the drive nozzle, thereby drawing the foam particles from the material container 2 into the transport pipeline 4. It is then transported in the direction of the molding jig 3 along with the driving air. The molding space 14 is closed, The mold halves 12 and 13 can move together completely, or through the crack gap. They can be driven apart from each other.

[0089] The slide of material container 2 can be opened and closed continuously. The opening and closing time is typically 50 This range is from 0 milliseconds to 1 second. This periodic opening and closing of the slide causes the material to escape from container 2. Foam particles are intermittently supplied to the transport pipeline 4. As a result, the crosslinking of foam particles in the material container 2 occurs. It can be cut, and the foam particles are separated. This is especially true for eTPU foam particles, for example. This is advantageous for foam particles having adhesive surfaces such as those described above.

[0090] Intermittent suction is alternatively performed by using a compressor located immediately next to the material container 2 from the compressed air pipeline 9. This can also be done by intermittently supplying driving air to the moving nozzle 8.

[0091] The molding jigs 12 and 13 are designed to allow compressed air flowing into the molding space 14 to escape. The device is provided with at least one valve (not shown) that is opened during the supply of foam particles. This valve is used during the filling of the molding space 14 so that a back pressure is formed within the molding space 14. This can be set. As a result, the pressure in the transport pipeline and the molding space 14 is kept high. This allows the volume of the foam particles to be kept small. This prevents back pressure from being applied. This makes it possible to supply more foam particles to the molding space 14 than in the case where it is not possible. After being removed, the foam particles expand within the molding space 14.

[0092] Further parameters for setting the filling amount include the crack gap, i.e., 2 during filling. This is the gap between the two mold halves 12 and 13, which are spaced apart from each other. Crack gap during filling By using this method, the density of the thin areas of the manufactured particle foam component becomes higher.

[0093] As soon as it is confirmed that the molding space 14 is filled with foam particles, the filling injector 1 0 is closed. The foam particles present in the pipeline are supplied to the filling injector 10. The material is blown back into container 2 by the air.

[0094] The filling of foam particles into the molding space 14 is described in German Patent Application Publication No. 102014117332. This is described in detail in the specification, so please refer to this patent application for further information.

[0095] After filling the molding space 14 with foamed particles, the foamed particles are heated by the application of electromagnetic RF radiation. This RF radiation is emitted at a frequency of 27.12 MHz for approximately 10 4 V high-frequency voltage is charged It is generated by applying it to subplates 15 and 16.

[0096] Electromagnetic RF radiation is preferably at least 30 kHz or at least 0.1 MHz. In particular, at least 1 MHz or at least 2 MHz, preferably at least 10 MHz It has a frequency.

[0097] The electromagnetic RF radiation preferably has a frequency of up to 300 MHz.

[0098] Foam particles for sportswear, sports equipment, or balls are polyurethane (eTPU). ) can be formed on a base. Polyurethane is an electric material with a frequency of 1 MHz. In the case of magnetic radiation, it has a dielectric loss D of 0.2. In contrast, electromagnetic radiation with a frequency of 1 MHz... In the case of radiation, the dielectric loss of polypropylene (PP) is only 0.00035. Therefore, the absorption rate of polyurethane is substantially higher than that of polypropylene. As a result, the foam particles themselves absorb electromagnetic waves, so no additional heat transfer material is needed, especially without an aqueous solution. This makes it possible to introduce the heat necessary to weld the foam particles into the mold space 14.

[0099] Instead of polyurethane-based foam particles, polyether block amide (PE) Using foamed particles based on BA or foamed particles based on polyethylene (PE) It can also be used.

[0100] Based on ePP (expanded polypropylene) or ePS (expanded polystyrene) Foamed particles can also be welded together to form foamed particle components. These materials emit electromagnetic radiation. Because it absorbs very little heat, it is advantageous to add a dielectric heat transfer medium, such as water. The foamed particles undergo heat transfer within the material container 2, or during transport from the material container 2 to the molding jig 3. It can be moistened with a medium. Wetting in conduit 4 occurs when the foam particles are moistened very uniformly. This has the advantage that the heat transfer medium is uniformly distributed within the mold space 14. The foam particles within the mold space 14 are heated uniformly.

[0101] The molding jig 3 can also be connected to a steam source (not shown), which allows for saturation. Dry steam can be supplied to the molding space 14. This is because the dielectric loss rate depends on temperature. This is advantageous when welding materials together. Such materials include, for example, ePES (expanded polyethylene). It is a methyl sulfone or foamed polyamide. At low temperatures, it has poor electromagnetic wave absorption properties. Therefore, these foaming particles are first heated by steam, and then at a specific temperature. It is then heated to an even higher temperature, either by itself or by electromagnetic radiation. The foam particles are moistened with a dielectric heat transfer medium so that the heat transfer medium is heated by electromagnetic radiation. The foam particles can also be heated to a predetermined set temperature. Then, as the temperature rises, electromagnetic waves are generated. Because the radiation absorption characteristics are increased, the foam particles can be directly heated by electromagnetic radiation.

[0102] The molding jig 3 (Figures 2a and 2b) will be described below, but the molding jig 3 is used in all situations. The set also has a first mold half 12 and a second mold half 13, and is used in the apparatus 1 described above. It is possible to use a moving device, a holding element, a thermometer for measuring the temperature in the mold space, and Further mechanical parts for opening and closing the jig are shown in Figures 2a and 2a for simpler illustration. It is omitted in b.

[0103] The molding jig 3 is formed from two mold halves 12 and 13, each composed of a conductive material. It has bodies 24, 25 made of aluminum, copper, or high It is made of a conductive alloy.

[0104] The two mold halves 12 and 13 define the boundary of the molding space 14 by their inner interface surfaces 26 and 27. The inner interface surfaces 26 and 27 of the two mold halves 12 and 13 are coated with an electrical insulating coating. G28 and G29 have been applied.

[0105] Electrical insulating coatings are materials that are virtually transparent to electromagnetic radiation, especially RF radiation, for example. However, these can be formed from PTFE, PE, PEEK, etc. The coating extends throughout the entire molding space 14 and to the edges of the molding space during the application of electromagnetic radiation. In order to achieve uniform heating in the region, when electromagnetic radiation is applied, within the molding space 14 A plastic material having a dielectric loss similar to that of the plastic material processed by It can also be formed from . For this purpose, coatings 28 and 29 are, for example, PE T (polyethylene terephthalate), PEEK (polyether ketone), POM (polio Moderate amounts of ximethylene, polyimide, and PMMA (polymethyl methacrylate) It is preferable that these coatings be formed from materials having a low loss rate. 28 and 29 absorb only a very small amount of electromagnetic radiation, so they are practically transparent to RF radiation. Yes, and because the loss rate is relatively low, for example, at least 2 mm, especially at least 2.5 mm. It can be formed with a specific thickness of at least 5 mm. The coating is a coating. Preferably 20m, so that the proportion of electromagnetic wave energy absorbed by the ng is reduced. The thickness is less than or equal to m, particularly less than or equal to 15 mm, and preferably less than or equal to 10 mm.

[0106] The conductive bodies 24 and 25 form the capacitor plate of the molding jig 3. Therefore, The conductive body has electrical connections so that it can be connected to the generator 18 or ground 30. The generator 18 represents a radiation source for generating electromagnetic radiation. Preferably, the generator is an RF radiation source. It is formed to generate radiation. The generator is formed to generate microwave radiation. It is also possible that, in the case of a larger mold space 14, RF radiation is substantially more effective than microwave radiation. Microwave heating allows for more uniform heating. In addition, most plastic materials can be heated by microwaves. It can absorb RF radiation substantially better than normal radiation. Therefore, RF radiation can be used It is preferable to use it.

[0107] The mold halves 12 and 13 define the boundary of the molding space 14 and simultaneously the condenser plate To form the "condenser plate", the distance between the "condenser plate" and the molding space 14 is very small. This is determined solely by the electrical insulating coatings 28 and 29. As a result, the loss of electromagnetic radiation The ratio is very low, and as a result, the proportion of electricity introduced as heat to the foam particles being welded is non It is always getting higher. Therefore, with such a jig, the foam particles can be welded very efficiently. It can be used to form particle foam components for sportswear, sports equipment, or balls. .

[0108] In this exemplary embodiment of the molding jig 3, the first mold half 12 has a bottom wall 31 and a circumferential side It has a wall 32. In this exemplary embodiment, both the bottom wall 31 and the side wall 32 are conductive It is formed from a body 24 and a coating 28 positioned on the inside. The side wall 32 is Non-conductive material, particularly plastic material, formed solely from, or partially from, a conductive body 24 It can also be formed by only. The second mold half 13 is formed by the first mold half 12 A movable plunger is formed within the cavity that is thus formed, thereby creating a molding space 1 4 is sealed. The seal between the two mold halves 12 and 13 is sealed so that at least the amount of material present inside is sealed. The foam particles are so dense that they cannot escape. The molding space 14 is not necessarily airtight. There is no need to do so.

[0109] The two mold halves 12 and 13 are moved relative to each other by a press (not shown). It is possible to apply a predetermined force.

[0110] The passage opening for supplying foamed particles (hereinafter referred to as the filling opening 33) is It is positioned in one mold half 12. The filling injector 10 is connected to the filling opening 33. This filling injector 10 has a filling opening, which will be described in more detail below. Because it lacks a closing mechanism to close 33, it differs from conventional filling injectors.

[0111] The first mold half 12 has one or more passage openings for releasing air. These passage openings will be referred to as ventilation openings 34 below.

[0112] The filling opening 33 and the ventilation opening 34 are in the closed state of the molding jig 3 (Figure 2b). A portion of the first mold half 12 that is covered by or covered by the second mold half 13 It is placed in the region, especially the edge region. As a result, the k By introducing the second molding jig 13 into the cavity, the molding jig 3 is closed, and the filling opens. The mouth 33 and the ventilation opening 34 are automatically closed. As a result, the filling injector 10 Therefore, it is not necessary to have a closing mechanism to close the filling opening 33.

[0113] This portion or area is the part of the first mold half 12 that is not covered by the second mold half 13. This is a region that opens up when one half of the mold moves away from the crack gap. That is the case.

[0114] Preferably, the first mold half 12 is connected to the ground 30. The filling injector 10 is The filling injector 10 is electrically connected to the ground 30, and the first mold half 12 It is coupled to the conductive body 24. The generator 18 emits electromagnetic waves or alternating current to the ground 30. A pressure is generated, and this electromagnetic wave or alternating voltage is applied to the body 25 of the second mold half 13. As a result, alternating electromagnetic fields, particularly RF radiation, are formed within the shaping space 14.

[0115] In this embodiment of the molding jig 3, the conductive bodies 24 of the two mold halves 12 and 13, It is important that 25 are electrically insulated from each other. In this exemplary embodiment, Insulation is achieved by coatings 28 and 29.

[0116] Preferably, one of the inner interface surfaces 26, 27 of the two mold halves 12, 13 is contoured. It is formed in such a way. Contouring in the sense of the present invention means any deviation from a flat interface. This refers to the shape of a ring. In this exemplary embodiment, the inner boundary surface 27 of the second mold half 13 is ring-shaped. It is bound. The inner boundary surface 26 of the first mold half 12 is ring-shaped in the region of the bottom wall 31. It is not bound.

[0117] Furthermore, in such a molding jig 3, the second molding jig 13 is formed like a plunger. The electrical body 25 is located within a cavity defined by the first mold half 12. A conductive book that is at least partially positioned and therefore functions as a capacitor plate. In that the body 25 is positioned very close to the molding space 14 or the foam particles to be welded, This differs from known molding jigs used to weld foam particles using magnetic waves.

[0118] Figure 3 shows the generator 18 and the capacitor plates 15 and 16 surrounding the mold halves 12 and 13. A jig capacitor formed by and an electromagnetic wave generator 1 suitable for transmitting electromagnetic waves. A transmission line (hollow waveguide or coaxial line) 46 from 8 to jig capacitors 15 and 16 This is schematically shown in the electrical circuit diagram. Preferably, the hollow waveguide forming the line 46 is on the conductive inside. It is formed as a coaxial air line having a tube and a conductive outer tube. The coaxial air line is high voltage The dimensions are determined to ensure reliable signal transmission. The wave impedance is preferred. Alternatively, it will be set to approximately 50Ω.

[0119] This track 46 has an inductance 47 on the generator side and an inductance 48 on the jig side. It is symbolically represented. These inductances are provided by the transmission line itself, The length of each track section determines the magnitude of each inductance. Jig-side capacitor Capacitor 49 is connected in parallel with jig capacitors 15 and 16. This capacitor 49 is This represents the electrical capacitance between the capacitor plate 15 and the housing 35 of the molding jig 3. Inductors 15 and 16, capacitor 49, and jig-side inductance 48 are used for jig oscillation. Forms road 50.

[0120] The generator-side capacitor 51 is connected in series with the generator 18 and the generator-side inductance. The generator-side capacitor 51 and the generator-side inductance 47 are connected to the generator oscillation circuit 5 Forms 2. At least the generator-side capacitor 51 or the generator-side inductance 47 For example, a capacitor with a variable distance between capacitor plates, or a transmission line of different lengths. By providing a interval, it becomes a variable design. Generator side capacitor 51 and generator side input It is also possible to make both the inductance 47 a variable design. A servo motor can be provided in the generator-side capacitor 51, and during its operation, for example, by linearly moving one of the two capacitor plates (in this case, both capacitor plates are always parallel to each other), or by pivoting one of the two capacitor plates, the distance between the two capacitor plates changes. By changing the capacitance of the capacitor 51 or the inductance 47, the resonance frequency of the generator oscillation circuit 52 can be changed or adjusted. When the resonance frequency of the generator oscillation circuit matches the resonance frequency of the jig oscillation circuit, the maximum power is transmitted from the generator 18 to the jig oscillation circuit 50, and thus to the jig capacitors 15 and 16. By changing the resonance frequency of the generator oscillation circuit 52, the power transmission can be controlled with a target. The greater the difference in the resonance frequencies of the two oscillation circuits 50 and 52, the lower the transmitted power. Therefore, the adjustment of the generator oscillation circuit 52 can be used with a target to set the power introduced into the forming space 14. In this exemplary embodiment, the resonance frequency of the generator oscillation circuit 52 is changed. It is similarly possible to change the resonance frequency of the jig oscillation circuit 50. This has the same effect regarding power transmission. However, it is more difficult to provide a variable capacitor or variable inductance on the jig side than on the generator side. Figure 4 schematically shows a configuration for controlling the power supplied to the jig capacitors 15 and 16.

[0121] By changing the capacitance of the capacitor 51 or the inductance 47, the resonance frequency of the generator oscillation circuit 52 can be changed or adjusted, and the resonance frequency of the generator oscillation circuit can be used to control the power transmission to the jig oscillation circuit 50 and the jig capacitors 15 and 16. By changing the resonance frequency of the generator oscillation circuit, the power transmission can be controlled with a target. The greater the difference in the resonance frequencies of the two oscillation circuits 50 and 52, the lower the transmitted power. Therefore, the adjustment of the generator oscillation circuit 52 can be used with a target to set the power introduced into the forming space 14. [[ID=**16**]]When the resonance frequency of the generator oscillation circuit matches the resonance frequency of the jig oscillation circuit, the maximum power is transmitted from the generator 18 to the jig oscillation circuit 50, and thus to the jig capacitors 15 and 16. By changing the resonance frequency of the generator oscillation circuit 52, the power transmission can be controlled with a target. The greater the difference in the resonance frequencies of the two oscillation circuits 50 and 52, the lower the transmitted power. Therefore, the adjustment of the generator oscillation circuit 52 can be used with a target to set the power introduced into the forming space 14. By changing the resonance frequency of the generator oscillation circuit 52, the power transmission can be controlled with a target. The greater the difference in the resonance frequencies of the two oscillation circuits 50 and 52, the lower the transmitted power. Therefore, the adjustment of the generator oscillation circuit 52 can be used with a target to set the power introduced into the forming space 14. The greater the difference in the resonance frequencies of the two oscillation circuits 50 and 52, the lower the transmitted power. Therefore, the adjustment of the generator oscillation circuit 52 can be used with a target to set the power introduced into the forming space 14. Therefore, the adjustment of the generator oscillation circuit 52 can be used with a target to set the power introduced into the forming space 14.

[0122] In this exemplary embodiment, the resonance frequency of the generator oscillation circuit 52 is changed. It is similarly possible to change the resonance frequency of the jig oscillation circuit 50. This has the same effect regarding power transmission. However, it is more difficult to provide a variable capacitor or variable inductance on the jig side than on the generator side. [[ID=**37**]]

[0123] Figure 4 schematically shows a configuration for controlling the power supplied to the jig capacitors 15 and 16. **Note**: There seems to be a duplicate line in the original text which is marked with **16** and **37** in the translation. It might be an error in the original text. You may want to double-check it.It is shown in the simplified circuit diagram. The generator 18 is connected to the jig capacitors 15 and 16. The measurement capacitor 53 has a capacitance that is a fraction of the capacitances of the jig capacitors 15 and 16 by a factor of 1, and is connected in parallel with the jig capacitors 15 and 16. The measurement capacitor 53 is connected to a voltage measuring device (voltmeter) 55 via a coaxial line 54. Preferably, a diode detector <00><000090>5## is connected in parallel with the measurement capacitor 5$$

[0124]

[0124] The measurement unit formed by the measurement capacitor 53 and the diode 56 is separated from the jig capacitors 15 and a <][<00009>[[ELMLINE]][[ID=1^ by an insulating capacitor 59$. The insulating capacitor has a high insulation [[ENDS]] s withstand voltage. The capacitance of the insulating capacitor 59 is smaller than the capacitance of the measurement capacitor 53 [[ID=]\ As^ a result, the voltage drop across the insulating capacitor is higher than that across the measurement capacitor 53 [[ID=>\ The ratio <000][ [[ID="" [[><0000|[[ID=\\ so that it is within the measurement range of the $$ <\\\\.\ |[[<>

[0125] [[ID=][ In this circuit, a voltage that corresponds to the voltage applied to the jig capacitors 15 and 16 and decreases according to the ratio of the capacitance of the measurement capacitor 53 to the capacitance of the insulating capacitor 59 drops across the measurement$ [[ID=3<!<". [[ID=^ =]​​​Only half occurs. Therefore, diode 56 occurs across the terminals of measuring capacitor 53. It forms a rectified voltage. This measured voltage is measured by the voltage measuring device 55 and the measurement signal It is converted to a number. The measurement signal is transferred to the control device 57, and the control device 57 controls the jig capacitor. A specific voltage across both ends, or a specific measurement which is a portion of the voltage across both ends of a jig capacitor. To generate a voltage across the measuring capacitor, a generator 1 is configured to output a predetermined power. Automatically controls 8.

[0126] The control device 57 controls the power of the generator 18 based on the measured voltage. In this case, the controlled The target values ​​for the predetermined power may differ. On the one hand, the power is set to a specific constant magnitude. It can be controlled, and on the other hand, the voltage drops across the ends of the measuring capacitor 53, and the voltage measuring device 5 The power can be varied such that the voltage rectified in step 5 remains substantially constant. In other words... This allows you to maintain a constant power output or measurement voltage depending on the measured voltage. ru.

[0127] As explained at the beginning, the absorption capacity of the material to be welded present in the jig capacitors 15 and 16 The force changes with temperature, and the absorption capacity of electromagnetic waves changes particularly strongly under certain processing conditions. This occurs. In the equivalent circuit diagram shown in Figure 4, the change in electromagnetic wave absorption capacity is due to the jig capacitor. This can also be considered as a change in capacitance between capacitors 15 and 16. This change in capacitance is the power output applied by the control device 57 to the jig capacitors 15 and 16. The voltage (=voltage amplitude) depends on whether it is designed to keep the voltage (=voltage amplitude) constant. This can lead to either a change in pressure amplitude or a change in power output.

[0128] In principle, it is easier for the generator 18 to output a predetermined constant power because , in that case, the adjustment of the jig oscillation circuit 50 with respect to the generator oscillation circuit 52 can be kept constant, and as a result, a constant power is output by the generator 18. In the present embodiment, the measured voltage measured by the voltage measuring device 55 can represent a parameter characteristic of the absorption capacity of the material to be welded, and this parameter is monitored by the control device 57. When the measured voltage changes by a predetermined threshold value within a predetermined time interval, this change is determined by the control device 57 and evaluated as a trigger point for ending the heating process. The heating process can be ended simultaneously with the determination of the trigger point or can be ended with a delay for a predetermined period. The heating process ends by turning off the power supply from the generator 18, and the turning off of the generator 18 is controlled by the control device 57.

[0129] In a modified form of the present embodiment, the control device 57 can be designed to first derive the measured voltage according to time. When the signal after the first-order time differentiation of the measured voltage exceeds a specific threshold value, this means a predetermined rapid change in the measured voltage existing between both ends of the jig capacitors 15 and 16, and this change is then evaluated by the control device 57 as a trigger point for ending the heating process.

[0130] In a further modified form of the present embodiment, the control device 57 can also be designed such that the second-order time differentiation of the measured voltage is determined. When the second-order time differentiation of the measured voltage exceeds a specific threshold value, this represents a predetermined curvature of the profile of the measured voltage, and thus a rapid change in the voltage signal. This signifies a change. This change is evaluated as a trigger point for terminating the heating process. It is also possible.

[0131] The control device 57 ensures that a substantially constant voltage (=voltage amplitude) is maintained across the jig capacitors 15 and 16. The power output by the generator 18 is designed to change so that it decreases in between. If present, the entire system is welded together by the corresponding change in power, jig capacitor 1 5,16 reacts to a rapid change in the electromagnetic wave absorption capacity of the material present within. This power is based Essentially, the voltage across the ends of the jig capacitors 15 and 16 is already known, Since it is measured by the measuring device 55, the current output to the jig capacitors 15 and 16 is measured. This can be determined by the following: Then, the corresponding current value and the corresponding voltage value The power can then be determined.

[0132] However, the power output of the generator 18 is controlled by the control device 57. It is easier to tap the signal. This control signal corresponds to the power that should be output. A predetermined strong change in the control signal is evaluated as a trigger point for terminating the heating process. This is possible. Since this control signal resides within the control device 57, it can also be monitored simultaneously here. It is possible.

[0133] Here, various embodiments are possible regarding how the trigger point is determined. It is possible to monitor whether your signal changes by a predetermined threshold within a predetermined time interval. Similarly, monitoring whether the first or second derivative exceeds a predetermined threshold is possible. can.

[0134] Similarly, (based on voltage or power, the signal is directly measured or the first or second derivative is obtained) (By monitoring the second derivative) once the trigger point is determined, the heating process begins simultaneously with the determination of the trigger point. You can either terminate the process immediately or delay it for a specified period of time before terminating it.

[0135] Heating period of foam particles for sportswear, sports equipment, or balls using electromagnetic waves This method for automatically determining sportswear, sports equipment, or balls This process is performed individually and again during each manufacturing process for producing foamed particle components from foamed particles. This can be done. However, within the scope of the present invention, this method can be used to create a specific molding jig, and for specific types or batches of sportswear, sports equipment, or balls Using electromagnetic waves on foam particles, for use in sportswear, sports equipment, or balls. It is also possible to calibrate the heating period of the foam particles. All foam particles are completely fused together. The heating process period until the foamed component is formed is mainly used to define the molding space. It depends on the molding jig used and the type or batch of foam particles used.

[0136] Manufacturing particulate foam components from foam particles for sportswear, sports equipment, or balls. The manufacturing process for this is called the calibration process, which uses electromagnetic waves to heat the foam particles. The intervals are set individually according to the method described above, and here electromagnetic waves are used to create foam particles. The duration required for heating is determined using a clock or clock generator. It is remembered. The period thus determined for heating the foam particles using electromagnetic waves is This will be referred to as the "manufacturing time interval" below.

[0137] It can perform a single calibration process or multiple calibration processes, and uses electromagnetic waves. The period during which the foam particles for sportswear, sports equipment, or balls are heated is in any case Multiple heating intervals are also detected. If multiple heating intervals are detected, these intervals are statistically evaluated. This allows, for example, the average or median of the detected heating intervals to be used in further manufacturing processes. It can be made available as a manufacturing time interval for further manufacturing processes. The characteristic parameters are no longer monitored; rather, the heating period of the foamed particles using electromagnetic waves is monitored. It is controlled based solely on this manufacturing time interval. Therefore, the processing of foamed particles using electromagnetic waves The thermal period is calibrated. As a result, further control is simplified, and where appropriate, the same Using jigs, we manufacture particulate foam components using foam particles of the same type or batch. These can then be transferred to further equipment for manufacturing particle foam components. The device is a simple control system that controls the heating process based only on the existing manufacturing time intervals. It can be designed using placement.

[0138] As explained above, each of the multiple manufacturing times is detected using a calibration process. The interval can be statistically evaluated. Through such statistical evaluation, the manufacturing process can be assessed. It is also possible to determine the quality factor. In short, this is an indication that the manufacturing process is unstable, resulting in the production of foamed particle parts with varying quality. In contrast, when the manufacturing time intervals are substantially the same, this means that the manufacturing process is stable. This means that each particle foam component is produced with the same quality. If the quality factor indicates that the manufacturing process is too unstable, then different calibration processes may be used during manufacturing. Converting the standard deviation of the interval into a quality factor for evaluating the quality of the manufacturing process. It is possible.

[0139] To optimize the manufacturing process, change one or more of the following parameters: It is possible. - Applied power of electromagnetic waves, - Applied voltage for generating electromagnetic waves, - Amount of heat transfer medium supplied to the molding space, - Amount of foam particles supplied to the molding space, - The pressure applied to the foam particles by the molding jig before the foam particles are heated.

[0140] The lower the applied power or voltage to generate electromagnetic waves, the slower the foam particles are added. It is heated. The slower the foam particles are heated, the more evenly the heat is distributed between different regions of the mold space. This allows for better welding and results in more uniform welding overall. Therefore, manufacturing professionals Seth stabilization can often be achieved by reducing power or voltage.

[0141] However, in the case of some molding jigs, particularly those having a conductive mold half, In addition, heat can be dissipated very well at specific points, thereby allowing for the specifics of the mold space. One point is cooled more strongly than the other. In contrast, in the case of such a molding jig, foam particles Heat as quickly as possible, and heat the foam particles with the highest possible electromagnetic power or as much as possible. In some cases, it is advantageous to operate with a high applied voltage. In this situation, power or electricity Increasing the pressure can lead to stabilization of the manufacturing process. The amount of foam particles to be placed and / or the amount of binder to bind the foam particles together also depends on the manufacturing process. This could significantly affect the stability of the foam particles, so increasing or decreasing the amount of foam particles or binder may have an effect. Similarly, there are cases where allowing this to happen leads to the stabilization of the manufacturing process. These quantities are product It can be recognized and set accordingly through a statistical evaluation based on quality coefficients.

[0142] This optimization can be performed automatically using an expert system. This can also be based on machine learning, and the quality of the manufactured particle foam parts can be determined manually or digitally. Detected by appropriate measurement methods using data technology and input into the system as feedback. It can be powered and, based on feedback, execute an optimization and learning process. .

[0143] The period during which electromagnetic RF radiation is applied depends on the volume of the molding space 14, the density of the foam particles, and the application. It was shown to depend on the power applied or the voltage applied. In the tests, the foaming particles were reliably And to achieve complete welding, depending on the volume and the material in which the foam particles are formed, it takes approximately 30 seconds. It was shown that approximately 2 minutes is required. In this case, a voltage of 3kV to 20kV is generally required. An amplitude is applied.

[0144] During welding, the temperature of the foam particles can be measured, and the power can be controlled accordingly. Preferably, the foam particles are controlled to have a temperature slightly higher than their softening temperature. ru.

[0145] The surface that defines the boundary of the molding space 14 can be further temperature-controlled. For this purpose, The heat wire 22 is placed in the molding jig adjacent to the surface that defines the boundary of the molding space 14. This is possible. The heating wire 22 is connected to the current source 23, and this current source heats the wire It can supply heating current to the device.

[0146] Instead of heating wires, fluid channels can also be provided within the mold halves 12 and 13. A corresponding temperature-controlled fluid flows through the channel. Preferably, the fluid is water or It is steam.

[0147] After the application of electromagnetic RF radiation, the molding space 14 is kept closed for a stabilization time interval. As a result, the introduced heat is uniformly distributed within the foamed particle component, and all foamed particles A very uniform weld is formed in between. This process step is called stabilization. During this time, a slight cooling of the particle foam components also occurs. The mold halves 12 and 13 are exposed to electromagnetic RF radiation. In contrast, it is formed from a material that is practically transparent and is usually a plastic material with low thermal conductivity. Therefore, in the closed molding space 14, virtually no heat is released to the outside. Of course, this is because one half of the mold is made from a material that is conductive and, consequently, highly thermally conductive. If it has been done, it is different.

[0148] The mold halves 12 and 13 formed from plastic are compared to the mold halves formed from metal. In short, it has the advantage of being significantly more insulating on the one hand and having a low heat capacity on the other. As a result, the desired temperature cycle can be performed substantially faster and with less energy. This process is completed, and the supplied heat is almost entirely delivered to the foam particles.

[0149] During the stabilization period, or for part of the stabilization period, capacitor plates 15 and 16 are The mold halves 12 and 13 are actively cooled by the cooling devices 32 and 33, thereby dissipating heat. It is extracted from the main body, and consequently from the particle foam component.

[0150] After stabilization, the particle foam component is demolded by separating the two mold halves 12 and 13. For demolding, a demolding plunger can be provided on the molding jig, and this demolding plunger The granular foam component is then extruded from one of the two mold halves 12 and 13.

[0151] Stabilization is an optional method step. Stabilization is performed for specific materials and molds. This can also be omitted. The larger the volume of the foamed particle component being manufactured, the more the particles will disintegrate after welding. It is more advantageous to stabilize the foam component within the molding jig.

[0152] To improve throughput, electromagnetic injection is used during filling and / or crack gap closure. RF radiation can be applied beforehand.

[0153] Electromagnetic radiation, particularly RF radiation, is applied while the molding space 14 is being filled with foam particles. It is possible to apply power only after filling, and initially with low power or low voltage. Then, the material is preheated to a specific temperature, and then the power or voltage is gradually or rapidly increased. .

[0154] Gradually increasing the power or voltage of electromagnetic RF radiation can also be advantageous, and the result As a result of gradually increasing the power or voltage of electromagnetic RF radiation, for example, 30 seconds to 3 minutes The lamp is run for a period of time. As a result, very uniform heating of the foam particles is achieved. It can be done.

[0155] Optionally, negative pressure and / or vacuum can also be applied to the molding space 14. This is advantageous when the supplied foam particles and / or compressed air have a specific moisture content. That is the case.

[0156] The method described above is a dry method compared to steam welding. As a result, The manufactured particle foam components are either dry or more dry after the manufacturing process. This allows for more rapid delivery to further processing steps. Furthermore, it allows for the demolding of warm particle foam parts. In some cases, it is advantageous to immediately supply it for further processing. As a result, on the one hand, The pauses between individual process steps can be shortened, while the foam particles can be welded together. The heat introduced for this purpose can also be used, at least partially, for subsequent method steps. Therefore, a significant improvement in efficiency can be achieved in manufacturing.

[0157] A water or steam supply pipeline is provided to the welding station, and water and / or steam are supplied to the molding jig. There are also cases where supplying air is advantageous. This is because it has a low dielectric loss rate at low temperatures, This is particularly advantageous when welding foamed particles that generally have a low dielectric loss rate. In such cases, a small amount of water or steam is supplied. As a result of electromagnetic radiation, the water is heated and turns into steam. The steam is further heated. As a result, the dielectric loss of the foamed particles becomes higher. It is heated to a relatively high temperature, which causes the foam particles themselves to absorb electromagnetic radiation, and further It is heated. For a molding space with a volume of 50 liters, several hundred grams of water is sufficient. This is shown. If the foamed particle material is, for example, ePS (expandable polystyrene), then 5 To heat and weld foam particles in a molding space with a volume of 0 liters, the amount must be 300g or less. Water is sufficient. In conventional welding, where foam particles are heated only by superheated steam, 50 A molding space with a volume of several liters requires a large amount of steam containing several kilograms of water.

[0158] Therefore, when welding foamed particles that absorb very little electromagnetic radiation, basically, Adding 300g of water once to a molding space with a volume of 50 liters is sufficient. Therefore, for many materials that absorb only a small amount of electromagnetic radiation, even a small amount of water is sufficient. It is possible. In the case of a molded space with other volumes, the maximum required amount of water should be applied to the volume in the same proportion. It can be combined.

[0159] When heating water by electromagnetic radiation within a molding space, the pressure present within the molding space is measured. It is convenient to use a molding jig that has a pressure sensor capable of doing so. This pressure is It is proportional to the temperature. Then, the irradiation of electromagnetic radiation is preferably controlled according to the measured pressure value. Therefore, it is preferably set to a specific pressure value. [Explanation of symbols]

[0160] 1 device 2 Material container 3. Molding jig 4 conduit 5 Bottom 6 Compressed air pipeline 7. Compressed air source 8 Drive nozzles 9 Compressed air pipeline 10 Filling Injectors 11 Compressed air pipeline 12 half-molds 13. Half-mold 14 Molding space 15 Capacitor Plate 16 Capacitor Plate 17 Electrical lines 18 AC voltage source 19. Vacuum pump 20 Fans 21 cooling fins 22 heating wires 23 Current source 24 Main unit 25 Main unit 26 Inner boundary surface 27 Inner boundary surface 30 Grounding 31 Bottom wall 32 Side wall 33 Filling opening 34 Ventilation openings 35 Housing 46 Pipeline 47. Inductance on the generator side 48. Inductance on the jig side 49 Jig-side capacitor 50 Jig Oscillator Circuit 51 Generator-side capacitor 52 Generator Oscillator Circuit 53 Measuring Capacitor 54 coaxial line 55 Voltmeter 56 diodes 57 Control device 58 Inductance 59 Isolation Capacitor

Claims

1. Using electromagnetic waves to generate particles from foamed particles for sportswear, sports equipment, or balls. A method for manufacturing foam components, - A step of filling the molding space, - A step of heating and welding the foam particles with electromagnetic waves, - Including the step of demolding, During the heating of the foam particles, the parameters characteristic of the absorption of electromagnetic waves are monitored, and the parameter When the meter changes by a predetermined amount, the heating of the foam particles is terminated. method.

2. The electromagnetic waves are generated by a capacitor located inside the molding space. The electromagnetic wave is applied to the capacitor with a predetermined voltage amplitude and introduced into the molding space. The power or the first or second derivative of said power with respect to time is measured as a characteristic parameter. to be, or The electromagnetic wave is applied to the capacitor with a predetermined power, and the voltage drop across the capacitor is The voltage or the first or second derivative of the voltage drop with respect to time is measured as a characteristic parameter. to be done, The method according to claim 1, characterized in that

3. After heating and before demolding, the particle foam component is cooled within the molding space. The method according to claim 1, characterized in that

4. RF radiation is used as electromagnetic waves. The method according to claim 1, characterized in that

5. Using electromagnetic waves to generate particles from foamed particles for sportswear, sports equipment, or balls. A method for calibrating a process for manufacturing foam components, At least one particle for sportswear, sports equipment, or ball as described in claim 1 The foamed component uses a mold that defines a specific molding space and foamed particles of a specific material type. The product is manufactured in a calibration process, and the duration of the heating by electromagnetic waves is such that the characteristic parameters are measured. The measurement is taken until the value changes by a certain threshold, and applies to sportswear, sports equipment, or balls. Further particle foam components for the r are manufactured corresponding to the period determined in the calibration process. During the heating interval, in all cases, the foamed particles are supplied with the same settings for the electromagnetic waves. A method of production that involves heating.

6. Multiple particle foam components for sportswear, sports equipment, or balls undergo a calibration process. The product is manufactured according to the method described in claim 1, and in any case the heating period is measured The manufacturing time interval is determined based on the multiple periods measured during the calibration process. to be done, The method according to claim 5, characterized in that

7. The average or median of each of the aforementioned periods is determined as the manufacturing time interval. The method according to claim 6, characterized in that

8. A predetermined multiple of the standard deviation centered on the mean or median of the measured period. Only the period within the specified time interval is considered for determining the manufacturing time interval. The method according to claim 6, characterized in that

9. In order to determine the quality factor of the manufacturing process, a statistical evaluation of the measured period is performed. It will be carried out. The method according to claim 6, characterized in that

10. If the quality factor indicates that the stability of the manufacturing process is too low, the manufacturing process By changing at least one specific parameter of the quality coefficient, The manufacturing process is optimized as follows: The method according to claim 9, characterized in that

11. The following parameters, - The applied power of the electromagnetic wave, - The applied voltage for generating the electromagnetic wave, - Amount of heat transfer medium supplied to the molding space, - The amount of foam particles supplied to the molding space, - Pressure applied to the foam particles by the molding jig before the foam particles are heated. 、 Modify at least one of the following, and then, according to the method of claim 1, sportswear By manufacturing multiple particle foam components for sports equipment or balls, during manufacturing The interval is determined again. The method according to claim 10, characterized in that

12. The at least one parameter to be changed and the degree of change are determined by the expert system Automatically determined by The method according to claim 11, characterized in that

13. Manufacturing particulate foam components from foam particles for sportswear, sports equipment, or balls. A device for that purpose, A molding jig for defining the boundary of a molding space, wherein at least two capacitor plates are located in front of it. The capacitor plate is positioned adjacent to the molding space and connected to a radiation source for electromagnetic radiation. A molding jig, in which the radiation source for electromagnetic radiation is designed to emit electromagnetic radiation, Equipped with, A control device is provided that is designed to automatically perform the method described in claim 1. Device.

14. Sportswear, sports equipment, or balls manufactured according to the method of claim 1 Foamed particle components made from foamed particles for use in applications.

15. The particle foam component according to claim 1, wherein the particle foam component is the sole of a shoe or a part of the sole of a shoe.

16. A shoe comprising the sole or insole described in claim 1.

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