Manufacturing method for foamed particle parts

Abstract

To provide a method for manufacturing foam particle components, in particular cushioning elements of sportswear such as a shoe sole, or cushioning elements, especially a shoe sole, produced by such a method.SOLUTION: A method for manufacturing a cushioning element for sportswear, such as a shoe sole, includes the steps of: supplying foam particles into a mold bore of a mold; and bonding the foam particles in the mold bore while applying a predetermined pressure. The foam particles include shredded recycled foam particles (recycled material) in a ratio of at least 10 wt.%, and the bonding of the foam particles is performed by electromagnetic waves.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for producing a foamed bead part. [Background technology]

[0002] A particularly suitable application field of the present invention is sportswear, such as shoe soles or midsoles. or sporting goods such as foam components of sporting balls, especially soccer balls. The present invention also relates to a method according to the present invention and / or a method according to the present invention for producing a cushioning element. Sportswear such as shoe soles or midsoles manufactured by the manufacturing equipment or the loosening of sporting goods such as foam components of sporting balls, particularly soccer balls. Includes impact elements.

[0003] Single-use products made of plastic, such as foam particle parts, e.g. packaging These plastic parts are considered to be harmful to the environment. They are being rapidly replaced by more environmentally friendly foam particle parts. Environmental compatibility is essential when a significant proportion of materials can be recycled. This can be high when the moulded part is made of one piece, as is the case with shoe soles, for example. This applies whether the product is intended for single use or long-term use.

[0004] For foamed particle parts made of expanded thermoplastic polystyrene (ePS), a maximum of 1 This is because the maximum amount of raw material used to manufacture foamed particle parts is 0% recycled. This means that 10% is made from recycled materials.

[0005] The recycled foam particles are shredded and mixed with new materials. Cycle foam particle material is called "regenerated material" The non-recycled foam particles are referred to as "original material." Hereby, the term "starting material" refers to the material that has not been remelted and extruded. , used to represent foamed particles that have not been or are not integrally bonded to form foamed particle parts. The starting foam particles have a closed surface and can be filled with a blowing agent. When the material is heated, any air trapped in the material or any blowing agent contained in the material is released. When heated, the walls of adjacent foamed particles press against each other and bond together. Foam particle parts (e.g. shoe soles, especially midsoles, or sports balls) , particularly the foam component of a soccer ball).

[0006] Shredded recycled foam particles (recycled materials) usually do not have a closed surface. It does not expand when heated. Depending on the intended use, the impact on the manufacturing of foamed particle parts may vary. The percentage of shredded recycled foam particle parts is low, believed to be zero or near zero.

[0007] However, at least with a higher percentage of recycled material, the foam particles can be bonded together to form foam particles. The necessary pressure for joining the sub-parts cannot be obtained, and the foam particles must be bonded together to achieve uniform bonding. When the recycled content is more than 10%, the particles are compressed together. Bonding does not occur in certain areas, resulting in a poor bond in the finished foam part. Therefore, there is a problem that the foamed particles in the foamed particle parts are not The small pieces that make up the

[0008] This is typically the case in the soles of modern sports shoes or the foam construction of sports balls. As with elements, they may be subjected to a large number of load cycles depending on their intended use and may require a single This is particularly undesirable in the case of foamed particle parts, which must be made to have a certain degree of stability. Due to this major drawback, it is difficult to manufacture such shoe soles using known methods. (or other cushioning elements of sportswear or sports equipment) ) Using recycled materials is completely impossible.

[0009] To address this, external pressure is applied to the foam particles so that they are sufficiently pressed together. If the proportion of recycled materials is large, exceeding 10%, A pressure of approximately 5 bar has been found to be adequate to achieve adequate bonding. has the disadvantage that the contact surface of the foam particles is inherently large. The steam introduced into the cavity (as in "steam chest molding") to bind the foam particles together is directed to the edges of the cavity. It may not penetrate deep enough into the components, resulting in foaming. The particles are more strongly bonded in the edge areas than in the center of the component. Poor bonding in the center results in poor quality foamed particle parts.

[0010] If you want to increase the proportion of recycled materials, you should basically thin out the foam particle parts that are eligible for recycling. This allows for the production of recycled materials. The foamed particles have a closed surface, thus overcoming the problems explained above. However, re-extrusion of recycled materials may require the addition of additives. These additives are expensive, and the foam particles produced in this way are prone to contamination. There is a risk that the quality may be inferior to foam particles made from non-recycled materials. Nevertheless, in the sense of the present application and the present invention, such particles are not considered to be starting materials. It can be understood as such and can be used as needed.

[0011] For example, International Publication No. 2014 / 128214 describes the use of saturated dry steam. A method and apparatus for producing expanded bead parts from expanded bead is described.

[0012] For example, U.S. Pat. No. 3,060,513, U.S. Pat. No. 3,242,238, British Patent No. 1403326, US Patent No. 5128073, and International Patent The brochure of Publication No. 2018 / 1001541 describes a method of bonding foam particles using electromagnetic waves. A method and apparatus for making foam particle components is described.

[0013] Also, WO 2019 / 122122 and German Patent Application Publication No. 102 No. 017205830, U.S. Patent Application Publication No. 2018 / 0327564, and DE 102016100690 A1 disclose further prior art. It is known. [Prior art documents] [Patent documents]

[0014] [Patent Document 1] International Publication No. 2014 / 128214 Brochure [Patent Document 2] U.S. Patent No. 3,060,513 [Patent Document 3] U.S. Patent No. 3,242,238 [Patent Document 4] British Patent No. 1403326 [Patent Document 5] U.S. Patent No. 5,128,073 [Patent Document 6] International Publication No. 2018 / 1001541 Brochure [Patent Document 7] International Publication No. 2019 / 122122 Brochure [Patent Document 8] German Patent Application Publication No. 102017205830 [Patent Document 9] US Patent Application Publication No. 2018 / 0327564 [Patent Document 10] German Patent Application Publication No. 102016100690 [Patent Document 11] German Patent Application ADI156759 Summary of the Invention [Problem to be solved by the invention]

[0015] The present invention provides a method and method for easily and reliably bonding expanded beads with a high proportion of recycled material with high quality. Based on the purpose of creating the device.

[0016] The detailed purpose is to manufacture sportswear (especially shoe soles) or sports equipment (especially Use in the manufacture of cushioning elements for sports balls, especially foam components of soccer balls The object of the present invention is to provide a method as described above and a device as described above. This is achieved by the following claims. Advantageous embodiments are set forth in the respective dependent claims. [Means for solving the problem]

[0017] The present invention relates to sportswear such as shoe soles or midsoles, or sportswear Foam particle parts for sports equipment, such as foam components of sports balls, especially soccer balls; In particular, the method for producing the cushioning element comprises: providing expanded particles into a mold cavity; bonding the expanded particles in the mold cavity while applying a predetermined pressure; Including, The foam particles contain at least 10% by weight of shredded recycled foam particles (recycled materials) ) and the bonding of the foam particles is carried out by means of electromagnetic waves.

[0018] In some embodiments, the particles obtained by shredding the expanded bead component may be originally monolithic. Multiple individual foam particles ("beads" or "beads") that are bonded together and remain closed after chopping. In some embodiments, these The particles can be shredded to such an extent that the original individual foam particles (beads or pellets) are separated. This usually results in damage to the surface of the individual foam particles, making such strong shredding unsuitable. The particles to be processed can be the aforementioned "recycled material" which does not have a closed surface.

[0019] The inventors of the present invention have found that when the expanded particles are bonded by electromagnetic waves, the electromagnetic waves are completely absorbed into the expanded particles. It penetrates completely and heats from the inside, so it can exert any pressure without affecting the bonding of the foam particles. It is recognized that foam particles may be applied depending on the quality, size, and proportion of recycled material. The pressure can be adjusted so that adjacent foam particles in the mold cavity are in sufficient contact with each other. By using magnetic waves as an energy source, it is possible to create complex three-dimensional shapes and structures with different thicknesses. This method allows the production of molded parts having a mesh area, and is therefore suitable for the shoe of a sports shoe. soles, especially midsoles (or other cushioning elements of sportswear with complex shapes) ) is particularly suitable for the production of

[0020] Recycled materials, i.e. shredded recycled foam particles, are especially suitable for shredding old moulded parts (even For example, old shoe soles or midsoles or sports shoes with particles already bonded together This is obtained by shredding old sports equipment such as foam components of sports equipment. handling of all parts, as this can be a particularly easy and cost-effective way of recovering is easy.

[0021] However, on the other hand, it is possible to use a system within the scope of the present invention (for example, to recycle excess stock of old materials). Older products that have not yet been molded into one piece (to eliminate the need for recycling and disposal) It is also possible to recover recycled material from the particles.

[0022] Here again, in principle, closed-surface particles re-extruded from molten recycled material It should be noted that it is also possible to use as a starting material.

[0023] From the experiments conducted by the applicant, it was found that the ratio of shredded recycled foam particles (recycled material) was the maximum Up to about 60% by weight, there is little quality improvement when joining foamed particle parts made of ePS. This makes solving a major problem very easy. So it is very surprising.

[0024] Polystyrene hardly absorbs electromagnetic waves. Therefore, ePS foam particles are not In the case of wave coupling, a heat transfer medium such as water is added to absorb the electromagnetic waves. The foam material is indirectly heated by electromagnetic waves. If the recycled material content is 70% or more, High levels of unwanted residual moisture can be contained in the foamed particle parts.

[0025] For materials such as expanded thermoplastic polyurethane (eTPU), It is particularly suitable for producing sports balls, especially soccer balls, and is more resistant to electromagnetic waves than polystyrene. These materials do not necessarily require additional heat transfer media for coupling. This eliminates the problem of residual moisture, making it possible to use foamed particle parts with a recycled content of more than 70%. Even if there is a problem, it can be manufactured reliably with high quality.

[0026] The proportion of chopped recycled foam particles may be at least 20% by weight, and particularly It may be at least 30% by weight, at least 50% by weight, or at least It may be at least 70% by weight.

[0027] The predetermined pressure in the mold cavity is preferably at least 2 bar, in particular at least 3 bar. and can be set to at least 5 bar. The higher the pressure, the better the quality of the shredded material. Higher percentage of recycled foam particles and / or more recycled materials It is possible to shred the

[0028] On the other hand, the set pressure is determined by the mechanical properties of the molded part being manufactured (for example, the stiffness of a shoe sole). This also affects the properties of the material, so we will use the following depending on the desired characteristics (high or low pressure). It is possible to use more recycled materials, or less recycled materials. It is also possible.

[0029] The electromagnetic waves are preferably electromagnetic RF radiation. The electromagnetic RF radiation has a frequency of at least 30 KHz. or at least 0.1 MHz, in particular at least 1 MHz or at least 2 MHz Preferably, the frequency is at least 10 MHz.

[0030] The electromagnetic RF radiation preferably has a maximum frequency of 300 MHz.

[0031] The generator that generates electromagnetic waves must have an amplitude of at least 10 3 V, especially at least 10 4 V It is preferable to generate electromagnetic waves of 27.12 MHz. Produces F radiation.

[0032] The electromagnetic wave may also be a microwave.

[0033] The foam particles are based on ePS (expanded polystyrene) or ePP (expanded polypropylene). These two materials only slightly absorb electromagnetic radiation. It is desirable to add a dielectric heat transfer medium such as water.

[0034] The foam particles are also compatible with other expanded thermoplastics, especially those that absorb electromagnetic waves well. It is also possible to form it in a more

[0035] Expanded polyurethane (ePU), extruded polyether block amide (ePEBA), Expanded polylactic acid (PLA), expanded polyamide (ePA), expanded polybutylene terephthalate (ePBT), expanded polyester-ether elastomer (eTPEE), or expanded poly Expanded particles based on ethylene terephthalate (ePET) can also be used. Since materials absorb electromagnetic waves well, the foam particles of these materials can transmit electromagnetic waves without the addition of a heat transfer medium. This is particularly true for the use of RF radiation. This allows electromagnetic waves to be uniformly emitted into mold cavities up to several meters in size.

[0036] Each material that is highly absorbing of electromagnetic radiation, especially RF radiation, affects the dipole moment. These have functional groups (here, amide groups, urethane groups, or ester groups). The functional groups are responsible for the absorption of electromagnetic radiation by the molecule and therefore for the absorption of electromagnetic radiation, especially RF radiation. The bonds that form are similar to those found in other thermoplastic polymers that have such functional groups that affect the dipole moment. Plastic is also suitable.

[0037] The shredded recycled foam particles are mixed with unshredded foam particles using a mixing device. The chopped material can be mixed in a fixed ratio and fed into a mold. The proportion of recycled foam particles can be freely adjusted and quickly changed.

[0038] It is also possible to chop the recycled foam particle material before feeding it into the mold cavity.

[0039] Another aspect of the invention is a sportswear or a sports ball, in particular a soccer ball. An apparatus for producing foam particle parts, in particular cushioning elements, for sports equipment such as foam components for sports equipment. So, a mold defining a mold cavity; means for applying a predetermined pressure to the expanded beads in the mold cavity; a generator for generating electromagnetic waves that bond the foam particles in the mold cavity; The present invention relates to an apparatus comprising:

[0040] This device processes shredded recycled foam particles and unshredded non-recycled foam particles. A mixing device for mixing particles and / or a shredding device for shredding foam material to be recycled It is characterized in that it is provided.

[0041] By providing a mixing device, the individual ratio of chopped recycled foam particles (= recycled material) can be The raw material and unshredded non-recycled foam particles (= starting material) are fed into the mold. The shredding device allows for rapid change of these ratios. Foam particle parts to be recycled can be shredded and supplied up to a size of The device is adjustable so that the chopping can produce foam particles of a specific size. .

[0042] The size of the chopped particles thus produced can affect the quality of the molded part (e.g. , shoe soles or sports balls, especially soccer balls (already shredded) This is advantageous because it is possible to influence the mechanical properties, for example to obtain a smaller diameter. Chopping the molded part in this way increases the rigidity of the molded part compared to chopping it to a larger diameter. It can become.

[0043] The device that applies a predetermined pressure to the foamed particles in the mold cavity is a device that combines two half molds into one. It is possible to press a mold configured as above to generate pressure in the mold cavity. The apparatus sets the mold cavity under a predetermined pressure by conveying a carrier gas that transfers the foamed particles to the mold cavity. In this way, the desired amount of foam particles can be filled into the mold cavity. The pressure is set.

[0044] The method described above can be adapted to use the device for this purpose.

[0045] As already mentioned several times, particularly important fields of application of the present invention are sportswear, cushioning elements, especially in shoe soles (e.g. midsoles or insoles) or cushioning elements of sporting goods such as foam components of sporting balls, especially soccer balls manufacturing, which is covered in more detail below.

[0046] Therefore, an important aspect of the present invention is to provide sportswear, in particular shoe soles or Sports balls, such as midsoles or foam components of sports balls, especially soccer balls 1. A method for manufacturing a cushioning element for an article, comprising: providing expanded particles into a mold cavity; bonding the expanded particles in the mold cavity while applying a predetermined pressure; Including, The expanded particles include at least 10% by weight of chopped recycled expanded particles, The coupling is performed by electromagnetic waves.

[0047] One possibility is to use foam containing shredded recycled foam particles to fill the entire cushioning element. However, other non-granular materials may be used. In this case, the weight percentages are based on the weight of the material used. It represents a granular material.

[0048] Here again, shredded recycled foam particles are made from shredded old molded parts (e.g. particles) Old shoe soles or midsoles or old sports balls with the soles or midsoles already bonded together The formation of molded parts by integral bonding has not yet been realized. It should be noted that it is also possible to obtain recycled material by shredding old particles of the application. In all cases, the (average) size of the shredded recycled material will determine the mechanical properties of the cushioning element to be manufactured. It can function as another moderating mechanism affecting sexuality.

[0049] On the other hand, the starting material is a closed-surface particle re-extruded from molten recycled material. It is also possible to use

[0050] Furthermore, the proportion of shredded recycled foam particles (i.e., recycled material) is small, respectively. at least 20% by weight, in particular at least 30% by weight, at least 50% by weight, and at least In this case, the predetermined pressure in the mold cavity is at least At least 2 bar, in particular at least 3 bar, is possible, preferably at least 5 bar. As mentioned above, the pressure used can be increased as the amount of recycled material increases. However, other factors, such as the desired mechanical properties of the product, also influence the selection of a suitable pressure. Boss.

[0051] In addition, foam particles are made of polystyrene (ePS), polypropylene (ePP), polyurethane, Polyurethane (eTPU), Polyether Block Amide (ePEBA), Polylactic Acid (PLA), Poly Polyamide (ePA), Polybutylene terephthalate (ePBT), Polyester-ether elastomer (eTPEE), or polyethylene terephthalate (ePET) and foam components of sportswear or sports balls, especially soccer balls, etc. The present invention can be used for cushioning elements in sports equipment.

[0052] Particularly suitable for use in cushioning elements, especially in shoe soles or soccer balls. Therefore, eTPU, ePA, and eP are selected based on the mechanical properties they can provide to the cushioning elements that make up the material. Expanded granules containing EBA and / or eTPEE or consisting of these materials A child is possible.

[0053] Joining process using electromagnetic waves, especially the use of fine particles of a material, on the premise that bonding is possible. The particles may be combined with unshredded particles of another material.

[0054] During the bonding using electromagnetic waves, a heat transfer medium can be added to the foam particles. The material can be a liquid, such as water, for example. Metals can also be used.

[0055] The addition of such tools allows for the influence and control of the degree of binding, albeit locally. This can also affect the mechanical properties of the manufactured product.

[0056] However, foam particles are not suitable for transmission, provided that a sufficient degree of bonding is already possible. It is also possible to couple by electromagnetic waves without the addition of a heat transfer medium. This is particularly simple and convenient from an engineering point of view.

[0057] In the manufacturing method of cushioning elements for sportswear or sports equipment, shredded ribbons are used. The cycled foam particles and unchopped foam particles are mixed in a predetermined ratio and fed into a mold. Mixing equipment can be used, for example recycled foam particle material (e.g. old shoe or foam components of sports balls (e.g., the foam components of old soccer balls) The sheet (in the form of a roll panel) can be chopped and then fed into the mould cavity.

[0058] Furthermore, the present invention relates to a method for producing sportswear, in particular shoe soles or mid-soles, from expanded particles. Sports equipment such as foam components of dosoles or sports balls, especially soccer balls An apparatus for manufacturing a cushioning element comprising: a mold defining a mold cavity; a device for applying a predetermined pressure to the expanded particles in the mold cavity; a generator for generating electromagnetic waves that bond the foam particles in the mold cavity; Equipped with A mixing device for mixing shredded recycled foam particles and unshredded foam particles, and and / or a shredding device for shredding the foam particles to be recycled. This includes devices that

[0059] The apparatus for producing a cushioning element further comprises a sorting device for sorting the chopped foam particles. It may be possible.

[0060] In such a device, by carrying out the method as described above, it is possible to foam soles or midsoles for sports balls, especially soccer balls As far as technically possible, cushioning elements of sports equipment such as components can be manufactured from: The various design options of the method according to the invention can be combined with one another.

[0061] Another aspect of the present invention is sportswear, particularly shoes, comprising integrally bonded expanded particles. Soles or midsoles for sports balls, especially soccer balls, or foam structures A cushioning element for sports equipment, such as a sports equipment component, in which the expanded particles account for at least 10% by weight of the cushioning element. The present invention relates to a cushioning element comprising shredded recycled foam particles.

[0062] In some embodiments, sportswear, particularly shoe soles or midsoles The cushioning element of the roll is made of at least one portion of a material containing shredded recycled foam particles. At least one portion may be made entirely of chopped recycled foam particles. At least one portion may be made up of different weight percentages of shredded recycled material. As mentioned above, the shredded recycled fiber in the above-mentioned portion may be composed of recycled fiber particles. The proportion of foam particles may be at least 10% by weight, or at least 20% by weight. It may be, in particular, at least 30% by weight, or at least 50% by weight. The shredded recycled foam particles may be at least 70% by weight. It may be mixed with the non-recycled foam starting material described above. The expanded particles may be mixed with another compatible polymeric material.

[0063] At least one portion of the shredded recycled foam particles comprises the entire shoe sole. At least one portion of the shredded recycled foam particles may be the entire midsole. At least one portion of the shredded recycled foam particles may comprise a shell. They may be located at specific locations within the sole or midsole. At least one part of the cycle foam particles is used to make sportswear, in particular shoe soles or Alternatively, the cushioning element may be located in the forefoot and / or rearfoot of the midsole. At least one portion of the shredded recycled foam particles is used to form a shoe sole or midsole. They may be located in the medial and / or lateral regions of the sole. At least one portion of the foamed particles may be located in a combination of the above locations.

[0064] Additionally, at least one portion of the shredded recycled foam particles comprises at least one The shoe sole or midsole may comprise a single layer. The shoe sole or midsole may include two or more layers. The entire layer may consist of a single piece of chopped recycled foam particles. A layer may include multiple portions of recycled foam particles.

[0065] For example, to cost-effectively produce a final sole with a sandwich layer structure: A pre-manufactured layer having at least one portion of chopped recycled foam particles is used. It may be like this.

[0066] At least two layers may have different thicknesses. In this case, the forefoot of the sole is made of shredded recycled foam granules relative to the rest of the sole. By having different thicknesses in the sole, the mechanical properties such as cushioning or rigidity of the sole portion can be improved. may be selectively adjusted.

[0067] It is also contemplated that portions of the cushioning element have substantially the same characteristics. one property (e.g., energy recovery, shear stability or stiffness, color, hardness, thickness, density) It is also conceivable that the portions of the cushioning element differ from one another with respect to the degree of cushioning. The percentage of chopped recycled foam particles can be varied from layer to layer to provide greater design flexibility. Alternatively or additionally, different types of shredded recyclables may be used. Using foam particles (e.g., chopped eTPU in one part and chopped eP in another part) Also, a mixture of chopped recycled foam particles can be used. As previously mentioned, the percentage of chopped recycled foam particles may vary depending on the desired The final properties of the material can be tailored to suit the required performance of the cushioning element.

[0068] This construction of chopped recycled foam particles also provides great design flexibility. Following the above idea, in certain areas of the sole, the specific needs of the wearer are addressed. Allows selective adjustment of mechanical properties. For example, running shoes can be designed to The shoe should have a good blend of stability and cushioning properties to avoid supination. do.

[0069] In some embodiments, foam components of sporting balls, particularly soccer balls. The cushioning elements of sporting goods such as sports equipment are made at least in part of a material containing shredded recycled foam particles. At least one portion may comprise shredded recycled foam. At least one portion may be made up entirely of chopped particles with different weight percentages. As mentioned above, the shredded foam particles in the above-mentioned portion may be made of recycled foam particles. The proportion of recycled foam particles may be at least 10% by weight, or at least 20% by weight. % by weight, in particular at least 30% by weight, or at least 50 % by weight or at least 70% by weight. The expanded particles may be mixed with the non-recycled expanded particle starting material described above. The recycled foam particles may be mixed with other compatible polymeric materials.

[0070] At least one portion of the shredded recycled foam particles is used to form a panel of a sports ball. At least one portion of the chopped recycled foam particles may be arranged as It may also comprise the entire panel of a sports ball. At least one portion may be disposed as part of a panel of a sporting ball. The panels are coated with a protective coating (e.g. polyurethane) against shredded recycled foam particles. It may further comprise a (PU) spray coating or foil coating (e.g., PU foil). At least one portion of the shredded recycled foam particles is used to form an entire foam component or a sports foam. The entire ball may be made of at least one of chopped recycled foam particles. The part may comprise the entire soccer ball. At least one portion of the foam component of a sports ball, particularly a soccer ball, At least one portion of the shredded recycled foam particles may be disposed at a position The foam structure of a sports ball, particularly a soccer ball, is formed in an essentially regular pattern. They may be placed at specific locations on the element. Irregular or randomly placed patterns It is also possible to

[0071] Additionally, at least one portion of the shredded recycled foam particles comprises at least one The foam component of a sports ball, particularly a soccer ball, may be arranged as a layer. The foam component of a sports ball, particularly a soccer ball, may comprise a single layer. The material may contain two or more layers. The entire layer may be made up of multiple pieces of chopped recycled foam particles. At least two layers may have different thicknesses.

[0072] For example, the final product of a sports ball, especially a soccer ball, having a sandwich layer structure The cost-effective production of foam components requires less shredded recycled foam particles. Pre-fabricated layers may be used that have one portion each.

[0073] It is also contemplated that portions of the cushioning element have substantially the same characteristics. one property (e.g., energy recovery, shear stability or stiffness, color, hardness, thickness, density) It is also possible that the cushioning elements may differ from each other. The percentage of chopped recycled foam particles can be varied from layer to layer to provide greater design flexibility. Alternatively or additionally, different types of shredded recyclable materials may be used. Using recycled foam particles (e.g., chopped eTPU in one part and chopped e in another part) PEBA) or a mixture of chopped recycled foam particles. As mentioned above, the proportion of the shredded recycled foam particles is The desired final properties can be tailored to suit the required performance of the cushioning element of the sporting goods.

[0074] Another aspect of the present invention is a method for manufacturing a sports ball, the method comprising one or more of the steps set forth above. 1. A method for producing a cushioning element of a foam component of a ball, in particular a soccer ball, comprising: The ball has no bladder and is made of shredded recycled foam particles. The shredded recycled foam particles may be placed as the core of a soccer ball. Alternatively or additionally, shredded recycled foam can be used for improved weight reduction. It is also conceivable that a soccer ball may contain layers of particles. These layers may be layers of different shredded materials. or may be interspersed with layers of non-shredded material (e.g., lightweight foam such as EVA) .

[0075] In particular, foam particles (i.e., shredded recycled foam particles and unshredded recycled foam particles) The foamed particles (eTPU, ePA, eTPEE, and / or ePEBA) It may be made of or consist of these. It is also possible to combine shredded particles of one material with unshredded particles of another material, provided that is.

[0076] The expanded particles may be bonded by the application of a certain pressure and the use of electromagnetic waves.

[0077] Generally, for the production of such a cushioning element, as far as technically possible, Depending on the intended property profile of the above-mentioned optional embodiments of the method according to the invention Options can be combined with each other.

[0078] The invention is explained in more detail below by way of example with reference to the drawings, which are diagrammatically shown as follows: be. [Brief explanation of the drawings]

[0079] [Figure 1] FIG. 1 is a block diagram illustrating an apparatus for manufacturing foam bead parts using recycled foam bead material. [Figure 2] 1A-1C show an exemplary embodiment of a cushioning element of a shoe sole or midsole according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0080] The present invention will be explained below using an example of an apparatus for manufacturing expanded bead parts (FIG. 1). The device is also referred to as an automatic molding machine 1.

[0081] As mentioned above, such a device and the method implemented therein are particularly suitable for sportswear, or the cushioning of sporting goods such as foam components of sporting balls, particularly soccer balls. 2. Where technically possible (i.e., where technically possible), the design options detailed above may be combined with each other. can.

[0082] The automatic molding machine 1 of FIG. 1 includes at least one mold formed by an upper half mold 3 and a lower half mold 4. The mold 2 is integrally joined together inside and forms a foamed particle part by heating. The mold cavity (not shown (e.g., the shape of the shoe sole 210)) is defined to receive the foam particles. Determine.

[0083] The mold 2 is a so-called crack gap mold, i.e., two half molds 3 and 4 are formed by the foam particles. After the particles are packed together, they are pressed together by press 5. The mold cavity is designed to apply pressure to the foam particles by means of a pressure adjusting mechanism.

[0084] The press 5 includes a press table 6 with a support plate 7 and a press plunger with a press plate 9. The press plunger 8 is a cylinder that can move the press plate up and down (bidirectional arrow 11). / Has a piston unit 10.

[0085] Additionally, a container 12 is provided for holding foam particle parts to be recycled. The container 12 opens into a funnel shape and is then chopped into foam particles of a predetermined size range. The bottom opens downwards towards a shredding device 13 designed to shred the foam particle parts. The chopped foam particles are irregularly shaped by the chopping method. The expansion is usually at least 3 mm, especially at least 4 mm, up to 10 mm or 8 mm The (average) size of the chopped foam particles is determined by, for example, the distance between the two chopping rollers. It can be controlled by adjusting the

[0086] The shredding device 13 is connected to a sorting device 15 via a line 14. Regarding the sorting device, for example, application number ADI156759 was filed on the same day as the present application. The entire contents of this patent application are incorporated herein by reference. The sorting device 15 can sort the chopped foam particles according to predetermined standards. One or more selection criteria can be applied. Expanded particles that do not meet the desired criteria are , and discharged via discharge line 16 into collection container 17.

[0087] The sorting device 15 is connected to a mixing device 19 by a line 18. The shredded recycled foam particles that meet the sorting criteria are transferred from the sorting device 15 to the mixing device 19. These foam particles constitute the recycled material.

[0088] The mixing device is connected to a storage tank 20 via a line 21 .

[0089] In lines 14 and 18, the expanded particles are transported by a carrier gas. , air. This carrier gas can be pressurized by a pump 22. The pump 22 is It is connected to line 21 via line 23.

[0090] The storage container 20 is used to provide non-recycled foam particles. The starting materials are fed to the mixer 19 via line 21.

[0091] In the mixer 19, the recycled material and the starting material are mixed in a certain ratio. The ratio can be freely adjusted.

[0092] The mixing device 19 is connected via a line 24 to a filling injector 25 opening into one of the two mold halves 3. In this example, the filling syringe 25 opens into the upper mould half 3.

[0093] The filling syringe is capable of supplying compressed air to the filling syringe 25 via a compressed air line 26. This air is called fill air and is pumped from the fill injector 25. The expanded particles are transported to the cavity of mold 2 and pressurized as necessary.

[0094] The support plate 7 is electrically conductive and is preferably a metal plate, for example steel or The support plate 7 is connected to the high frequency generator 2 via a coaxial line 28. It is connected to 9.

[0095] Radio frequency generators are designed to produce RF radiation. It is connected to the electrical ground 30.

[0096] The press plate 9 is also electrically conductive and can likewise be a metal plate, in particular an aluminum or steel plate. and connected to electrical ground.

[0097] In this way, the support plate 7 and the press plate 9 are subjected to a high frequency electromagnetic field or constitute a capacitor plate between which RF radiation can be applied.

[0098] The two mold halves 3, 4 are made of a material that is essentially transparent to RF radiation. The material may be, for example, polytetrafluoroethylene (PTFE), polyethylene, especially UHMW. PE, polyetherketone (PEEK).

[0099] This automatic molding machine 1 can be used to make, for example, sportswear, particularly shoe soles (e.g., cushioning elements of sports balls, especially footballs For the manufacture of cushioning elements for sports equipment, such as foam components for balls, the following method is carried out: It is possible.

[0100] The foam particle parts to be recycled are placed in a container 12 and transferred from there to a shredding device 13. In the shredding device 13, the foam particles are shredded into foam particles. The recycled material is then shredded to a predetermined size. The recycled material is then fed to a sorting device 15. This removes impurities or foam particles that do not meet the specified standards. The size, shape, color, density, etc. of the particles can be varied. Magnetic particles can also be removed. It can be done.

[0101] The recycled material thus produced is fed via line 18 to a mixing device 19, It can be mixed with the starting material in a predetermined ratio. The mixing ratio itself can be set as desired. The percentage of activating material can be as low as 0%.

[0102] The expanded particles are fed from a mixer 19 to a mold 2, where a carrier gas is pumped through pumps 22, 2 Pressurized by 7, the expanded particles are fed under pressure into the mold cavity.

[0103] When the foam particles are fed, the two half molds 3 and 4 are slightly separated. Once filled, the two half molds 3 and 4 are pressed together slightly by the press 5, The size of the mold cavity is reduced and the pressure on the expanded particles in the mold cavity is increased.

[0104] A high frequency generator 29 applies RF radiation to the pressurized foam particles, causing the foam particles to They are heated and bonded together.

[0105] The RF radiation heats the foam particles in the mold cavity, which can be achieved by direct absorption of the RF radiation or by the RF radiation. Heating is accomplished by the addition of a heat transfer medium such as water, which absorbs the radiation and transfers it to the foam particles.

[0106] For bonding of the foam particles, it is not necessary to supply steam from the outside to the mold 2. Foam particles in the mold cavity The pressurization of the pressure has no effect on the heat supply by electromagnetic radiation.

[0107] Thus, the combination of electromagnetic radiation and pressure application to the foam particles in the mold cavity allows for regeneration. It is possible to bond expanded particles with a high proportion of material. Examples are described in more detail below. do.

[0108] The above example can be modified in various ways within the scope of the present invention. For this purpose, it is sufficient to provide only a pump or press. There is no need to fill the mold with a press and then compress the mold with a press. High pressure is generated in the mold cavity by the combination of filling and compressing the crack gap with the press. can be applied.

[0109] Furthermore, in connection with the present invention, it is not necessary for the mold halves to be transparent to electromagnetic waves. The mold can be constructed of metal and can itself function as a capacitor plate. In the case of sexual intercourse, they must be insulated from each other.

[0110] Optionally, nozzles 31 are provided at one or more points on lines 18, 21, and 24. By providing a valve, water or another fluid can be supplied. It can be supplied as

[0111] The addition of fluid can, on the one hand, facilitate the transport of the foam particles in the line. Such expanded particles tend to agglomerate. If the surface of the expanded particles is wetted with water or other liquid, This tendency is reduced and pumping becomes more reliable. It can act as a heat transfer medium during bonding of the polymers. Certain plastic materials, such as ePP, only slightly absorb electromagnetic radiation. The heat transfer medium is capable of absorbing electromagnetic radiation in the mold cavity and transferring it to the foam particles. If a highly absorbent material is used, no additional heat transfer medium is required. [Example]

[0112] Plates with dimensions of 1000 x 500 x 60 mm (= 30 liters) were produced. Both the recycled material and the foamed ePS particles were used. During filling, only a 9mm crack gap was observed. The expanded volume of the mold cavity was 34.5 liters.

[0113] When the mold halves were joined, the foam particles were introduced under pressure.

[0114] The percentage of recycled materials is 0%, 10%, 20%, 30%, 40%, 50%, 60%, Plates of 70%, 80%, 90%, and 100% were produced.

[0115] Water was added as a heat transfer medium. The amount of water was 150 ml to 250 ml. The higher the ratio, the more water was added.

[0116] All boards are now bondable. Sheets with a recycled content of 70% or more have a better surface. It is coarser and contains much more residual moisture, which is then trapped in the open-pore foam particles of the recycled material. It was left.

[0117] The boards with up to 60% recycled content met all quality requirements, but the boards without recycled content It is nearly impossible to distinguish it from the old board.

[0118] FIG. 2 shows a shoe having a sole 210 or midsole as a cushioning element according to the present invention. 2 illustrates an exemplary embodiment of a shoe 200. The sole 210 of the shoe 200 is a one-piece The expanded particles 220 are bonded together by at least 10% by weight of the expanded particles. In the embodiment of FIG. 2, the shredded recycled foam particles 230 are The proportion of recycled foam particles 230 is at least about 40% by weight of the sole 210 .

[0119] The sole 210 is made of shredded recycled foam particles 2 arranged in at least one layer. The first portion is disposed in the forefoot portion 240 of the sole 210. a second portion disposed in the midfoot portion of the sole 210, and a third portion (not shown) disposed in the midfoot portion of the sole 210. The corresponding first layer is disposed in the heel or rear foot portion 250 of the sole 210. The upper portion extends from the forefoot 240 to the midfoot. In the sole 210, from the forefoot portion 240 to the heel portion or the tip of the rear foot portion 250 of the sole 210 A third layer (not shown) is located on the underside of the sole 210 and extends down to the head. from the forefoot portion 240 to the heel or rearfoot portion 250, in other words, the entire lower surface of the sole 210 Those skilled in the art will recognize that these three sections and layers are exemplary. It will be appreciated that other moiety and layer configurations are contemplated.

[0120] Other exemplary embodiments of the present invention are listed below, which are not intended to limit the scope of the present invention. This will help you gain a deeper understanding of the potential benefits.

[0121] 1. Sportswear, especially shoe soles or midsoles or sports balls Method for producing foam particle parts for sports equipment, such as foam components for soccer balls, in particular - Patent application And, providing expanded particles into a mold cavity; bonding the expanded particles in the mold cavity while applying a predetermined pressure; Including, The expanded particles include at least 10% by weight of chopped recycled expanded particles, The method, wherein the coupling is performed by electromagnetic waves.

[0122] 2. The proportion of chopped recycled foam particles is at least 20% by weight, in particular at least 30% by weight, at least 50% by weight, or at least 70% by weight. The method described in Example 1.

[0123] 3. The predetermined pressure in the mold cavity is preferably at least 2 bar, in particular at least 3 bar. 3. The method according to claim 1 or 2, characterized in that the pressure is at least 5 bar.

[0124] 4. The foam particles are made of polystyrene (ePS), polypropylene (ePP), polyurethane (eTPU), polyether block amide (ePEBA), polylactic acid (PLA), poly Amide (ePA), Polybutylene Terephthalate (ePBT), Polyester-Ether Based on elastomer (eTPEE) or polyethylene terephthalate (ePET) The method according to any one of Examples 1 to 3, characterized in that

[0125] 5. An example of a method for bonding a heat transfer medium to foam particles during electromagnetic bonding. The method according to any one of 1 to 4.

[0126] 6. The method according to example 5, characterized in that the heat transfer medium is a liquid such as water.

[0127] 7. The foam particles are bonded together using electromagnetic waves without the need for additional heat transfer media. The method according to any one of Examples 1 to 4,

[0128] 8. Mixture of shredded recycled foam particles and unshredded non-recycled foam particles Any of Examples 1 to 7, characterized in that the ingredients are mixed at a predetermined ratio by a mixing device and supplied to a mold. The method according to any one of claims 1 to 5.

[0129] 9. An example of a method for manufacturing a mold cavity in which recycled foam particle material is shredded and then fed into the mold cavity. 9. The method according to any one of 1 to 8.

[0130] 10. Sportswear products made from foam particles, in particular in the form of shoe soles or midsoles or sports equipment such as foam components of sports balls, especially soccer balls. 1. An apparatus for producing an expanded bead part, comprising: a mold defining a mold cavity; means for applying a predetermined pressure to the expanded beads in the mold cavity; a generator for generating electromagnetic waves that bond the foam particles in the mold cavity; Equipped with Mixing shredded recycled foam particles and unshredded non-recycled foam particles A mixing device for shredding the foam particles to be recycled and / or a shredding device for shredding the foam particles to be recycled are provided. An apparatus characterized by:

[0131] 11. Example 10, characterized in that a sorting device for sorting the chopped foam particles is provided. 2. The foamed particle part manufacturing apparatus according to claim 1 .

[0132] 12. Any of Examples 1 to 9, characterized in that the device according to Example 10 or 11 is used. The method according to any one of claims 1 to 5.

[0133] 13. Sportswear, especially shoe soles, containing integrally bonded foam particles The cushioning element of the midsole is made of expanded particles with a shredded particle content of at least 10% by weight. A cushioning element comprising recycled foam particles.

[0134] 14. Example 13, with at least one section having shredded recycled foam particles The cushioning element according to claim 1.

[0135] 15. At least two portions of shredded recycled foam particles with different weight percentages. Also, the cushioning element described in Example 13 or 14.

[0136] 16. At least one portion of the shredded recycled foam particles is used to form at least one layer 15. The cushioning element of Example 13 or 14, arranged as follows:

[0137] 17. At least two layers of shredded recycled foam particles have different thicknesses. The cushioning element of Example 16.

[0138] 18. Sportswear, especially shoe soles or midsoles, are intended to be shredded. The recycled foam particles of Examples 13 to 17 were placed in the forefoot and / or rearfoot. The cushioning element according to any one of claims 1 to 4.

[0139] 19. Targeting sports balls, shredded recycled foam particles are used to make sports balls. The cushioning element according to any one of Examples 14 to 17, arranged as a core of a roll.

[0140] 20. The expanded particles include eTPU, ePA, eTPEE, and / or ePEBA. 20. The cushioning element of Example 19, comprising:

[0141] 21. Examples 19 and 20, in which the foam particles are bonded by applying a predetermined pressure and using electromagnetic waves. 21. A cushioning element according to claim 20.

[0142] 22. Any of Examples 19 to 21, produced using the method described in any one of Examples 1 to 9. The cushioning element according to any one of claims 1 to 4.

[0143] 23. Sportswear according to any one of Examples 13 to 22, in particular a shoe sole ( 210) or shoes (200) with cushioning elements in the midsole, especially sports shoes Jews.

[0144] 24. Using the method of any one of Examples 1 to 9, A method for producing the cushioning element of the foam component of the sports ball, in particular a soccer ball, as described Law.

[0145] Here again, one particularly important aspect of the present invention is the manufacture of cushioning elements for sportswear, In particular for the manufacture of shoe soles, all the features described in the list of exemplary embodiments above can be used. Features and design options may be used individually and / or in various combinations and sub-combinations. emphasizes that the present invention is applicable in the context of the manufacture of cushioning elements for such sportswear. Leave it there. [Explanation of symbols]

[0146] 1 Automatic molding machine Type 2 3 Upper half mold 4 Lower half mold 5 Press 6 Press table 7 Support plate 8 Press Plunger 9 Press Plate 10 Cylinder / Piston Unit 11 Double Arrow 12 containers 13 Shredding equipment 14 lines 15 Sorting equipment 16 Discharge line 17 Collection Container 18 lines 19 Mixing equipment 20 Storage Tank 21 Line 22 Pump 23 Branch Line 24 lines 25 filling syringe 26 Pressure Vessels 27 Pump 28 Coaxial Line 29 High frequency generator 30 Electrical Grounding 31 nozzles The above list of reference numbers is an integral part of this application.

Claims

1. A method for producing a mold comprising two half molds, the method comprising the steps of: supplying foamed particles to a mold cavity formed by the two half molds that have been separated; pressing the two mold halves together to reduce the size of the mold cavity formed by the two mold halves and apply a predetermined pressure to the expanded beads in the mold cavity; applying electromagnetic RF radiation to the pressurized expanded particles within the mold cavity; Including, The expanded beads include recycled expanded beads. A method for manufacturing a cushioning element.

2. The method described in claim 1, wherein the recycled particles include shredded recycled particles obtained by shredding old molded parts and / or closed-surface particles re-extruded from molten recycled particles.

3. The method described in claim 2, wherein the proportion of shredded recycled foam particles is at least 10% by weight.

4. A method described in any one of claims 1 to 3, wherein the predetermined pressure in the mold cavity is at least 2 bar.

5. A method according to any one of claims 1 to 3, wherein the electromagnetic RF radiation is at least 30 KHz.

6. The method of any one of claims 1 to 5, wherein the expanded particles are based on polystyrene (ePS), polypropylene (ePP), polyurethane (eTPU), polyether block amide (ePEBA), polylactic acid (PLA), polyamide (ePA), polybutylene terephthalate (ePBT), polyester-ether elastomer (eTPEE), or polyethylene terephthalate (ePET).

7. A method described in any one of claims 1 to 6, wherein in the step of applying the electromagnetic RF radiation, a heat transfer medium is added to the foam particles.

8. An apparatus for producing a cushioning element using the method according to any one of claims 1 to 7, comprising: a mold defining a mold cavity; a means for applying a predetermined pressure to the expanded beads positioned in the mold cavity; a generator for generating electromagnetic RF radiation that bonds the foam particles in the mold cavity; Equipped with An apparatus characterized by comprising a mixing device for mixing recycled and non-recycled foam particles and / or a shredding device for shredding foam material to be recycled.

9. A method for producing a cushioning element for a foam component of a sports ball using a method according to any one of claims 1 to 7.

10. A method for producing a cushioning element of a foam component of a shoe sole using a method according to any one of claims 1 to 7.

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