DE102014007472A1 - Method and production of a thermoformed article - Google Patents

Abstract

The process enables the creation of a customizable article, such as an insole for shoes, a seat, a bicycle seat, etc., and in any case takes three layers of different materials, a bottom layer, an intermediate layer and one, on the finished product upper layer, part, which are placed on an aluminum mold and wherein a deformation process between 100 and 360 seconds, at a temperature between 120 ° and 200 ° C and at a pressure between 20 and 70 bar, takes place, after the deformation the opening of the Molding, demolding and conditioning of the product produced is carried out in order finally to carry out the punching and to obtain the finished product with the shape of the shape and the desired model. The layers can consist of different types of material and the intermediate layer is deformable because it has thermoplastic resins.

Description

SCOPE OF THE INVENTION

The present invention relates to a method for producing a thermoformed article, such as an insole for shoes, a seat, a bicycle seat, etc., wherein the thermoformed article is simultaneously deformable and by the superposition and deformation of three layers, as many materials which participate in the production of the finished article or product.

BACKGROUND OF THE INVENTION

There are numerous ways and procedures to obtain thermoformed articles by molding, which articles can be any item that is even customizable, such as seats for vehicles, bicycle seats, and most importantly shoe insoles.

However, the methods for producing the above article are expensive and expensive, and they do not guarantee a finished product or article with the desired features and benefits.

The existence of methods based on the present invention is not known.

DESCRIPTION OF THE INVENTION

The method of the invention is carried out from three layers, an upper layer, an intermediate layer and a lower layer, starting from different materials, wherein the upper layer may be made of fabric and polyurethane foam or sponge or fabric and recycled polyurethane foam with carbon, while the intermediate layer a polyester nonwoven fabric with thermoplastic resins or a polyester, cotton or polyamide fabric with thermoplastic resins. In turn, the bottom layer may be woven or polyurethane foam, or woven and polyurethane foam.

• – Anordnen auf die Aluminiumform der unteren Lage, um nachfolgend die Zwischenlage anzuordnen, welche aus einem verformbaren Material gebildet ist, um schließlich die obere Lage anzuordnen, immer unter Betrachtung der Merkmale des für jede Lage ausgewählten Materials.
• – Nach Anbringung der drei Lagen, überlagert und in der vorher genannten Reihenfolge, wird die pneumatische oder hydraulische Presse der Form betätigt, während einer Verformzeit von 100 bis 360 Sekunden, und bei einer Temperatur, sowohl im oberen Bereich als auch im unteren Bereich der Form, von 120° bis 200°C, und bei einem Druck während der Verformung von 20 bis 70 Bar.
• – Nach dem vorher genannten Verformungsschritt werden das Öffnen der Form und das entsprechende Entformen des Produkts durchgeführt.
• – Nach dem Entformen findet ein Abkühlen und Konditionieren des Produkts statt.
• – In einem folgenden Schritt wird das Stanzen des fertigen Produkts mit der vorbestimmten Gestalt und Ausbildung, gemäß der Ausbildung der Form und des Models des zu erzeugenden Produkts, durchgeführt.

In the method for producing the article, an aluminum mold is used, which has the formation of the article to be produced, the process in the narrower sense being characterized by the following operational steps:

• Placing on the aluminum mold of the lower layer to subsequently arrange the intermediate layer formed of a deformable material to finally arrange the upper layer, always considering the characteristics of the material selected for each layer.
• - After mounting the three layers, superimposed and in the order mentioned above, the pneumatic or hydraulic press of the mold is actuated, during a deformation time of 100 to 360 seconds, and at a temperature, both in the upper region and in the lower region of the mold , from 120 ° to 200 ° C, and at a pressure during the deformation of 20 to 70 bar.
• - After the aforementioned deformation step, the opening of the mold and the corresponding demolding of the product are carried out.
• - After demolding cooling and conditioning of the product takes place.
• - In a subsequent step, the stamping of the finished product is carried out with the predetermined shape and design, according to the design of the mold and the model of the product to be produced.

DESCRIPTION OF THE DRAWINGS

In order to supplement the description to be given below and to better understand the features of the invention according to a practical, preferred embodiment thereof, a single drawing is added as an essential part of said description, in which, by way of illustration and not limitation, the block diagram is shown corresponds to the various steps of the method according to the invention.

PREFERRED EMBODIMENT OF THE INVENTION

As can be seen in the cited figures, the blocks ( 1 . 2 and 3 ), which correspond to the layers of the various materials that participate in the production of the finished article or product, the block ( 1 ) of the top layer, which, as already mentioned, may be made of outer fabric and polyurethane foam or sponge, or an outer fabric and recycled polyurethane foam with carbon, while the block (FIG. 2 ) the layer of intermediate material in a stiff state and may consist of nonwoven fabric made of polyester with thermoplastic resins, or of fabric made of polyester, cotton or polyamide with thermoplastic resin, wherein the block ( 3 ) may correspond to the lower layer, which may be of a fabric, either of polyurethane foam or of a textile and polyurethane foam.

In any case, the three layers mentioned ( 1 . 2 . 3 ) are arranged in the order indicated on a mold with the formation characteristics of the finished product, article or article to be produced, wherein a deformation step ( 4 ) is carried out for a time of 100 to 360 seconds, at a temperature between 120 ° and 200 ° C and at a pressure between 20 and 70 bar, so that after deforming the opening of the mold according to step ( 5 ) and after this the demolding according to step ( 6 ), after which the conditioning in a subsequent step ( 7 ), and finally punching according to step ( 8th ) of the article, article or product, which will have a design corresponding to the shape used, and the finished product ( 9 ) is produced.

embodiment

• – Erwärmen der Einlegesohle nach Wärmezufuhr mit einer Trockenbestrahlungsquelle (Mikrowelle, warme Luft, usw.), wodurch das Material der Zwischenlage verformbar wird, und nicht mehr wie am Anfang steif ist, wobei es an die jeweilige Fußanatomie anpassbar ist.
• – Nach Anwendung der Wärmequelle, wird die Einlegesohle in den Schuh eingeführt und nachfolgend wird mit dem Fuß des Benutzers gedrückt, so dass sich die Einlegesohle an die Anatomie dieses Fußes und an die zu verwendende Schuhe anpassen wird.
• – Schließlich lässt man die Einlegesohle abkühlen, wobei das thermoplastische Material seinen anfänglichen steifen Zustand zurückgewinnt und auf diese Weise eine an den Benutzer angepasste anatomische Einlegesohle hergestellt wird.

For example, if it is an insole for shoes, with the three materials corresponding to the upper layer, the intermediate layer and the lower layer, and the corresponding shape, said insole will have a completely rigid, stable and stable structure under normal conditions, and after the application of heat, it will be possible for it to transform into a fully deformable insole that conforms to the user's feet and shoes; this characteristic is due to the thermoplastic resins present in the intermediate layer, which are quite deformable at temperatures between 60 ° and 70 ° C and completely rigid at room temperature, so that the following steps are to be carried out for the use of said insole:

• Warming the insole after heat supply with a dry irradiation source (microwave, warm air, etc.), whereby the material of the intermediate layer becomes deformable, and is no longer stiff as at the beginning, being adaptable to the respective Fußanatomie.
• After applying the heat source, the insole is inserted into the shoe and subsequently pressed with the user's foot so that the insole will conform to the anatomy of that foot and to the shoes to be used.
• Finally, the insole is allowed to cool, recovering the thermoplastic material from its initial stiff state, thus producing a customized anatomical insole.

This process is carried out batchwise and in series, with the operator inserting and demolding the various presses as the thermoforming is performed.

Claims (3)

A method of producing a thermoformed article, wherein the method is performed in an aluminum mold, and wherein three layers of different materials are used in forming the finished article or product, characterized in that it comprises the following operational steps: - arranging the three superimposed layers of material the shape, - deforming the composite of the three superimposed layers during a time between 100 and 360 seconds, at a temperature between 120 ° and 200 ° C and at a pressure between 20 and 70 bar, - opening the mold and corresponding demolding, - cooling and conditioning the demolded product, - stamping the product produced to obtain the finished article or product having the shape of the mold. A method for producing a thermoformed article according to claim 1, characterized in that in the production of an insole for shoes, the lower layer of a fabric or polyurethane foam, or a combination of fabric and polyurethane foam, while the intermediate layer of a nonwoven fabric made of polyester with thermoplastic resins or from a woven fabric of polyester, cotton or polyamide with thermoplastic resins, wherein the top layer may consist of a woven and polyurethane foam or sponge or of a woven and recycled polyurethane foam with carbon. Method for producing a thermoformed article according to claim 2, characterized in that the insole produced by superimposition, deformation and shaping in the mold, with the three overlaid layers, the upper layer, the intermediate layer and the lower layer, is heated with a dry irradiation source wherein, after heating, the insertion of the insole into the respective shoe is performed, the user's foot exerting pressure to conform the insole to the anatomy of the foot and the shoes to be used to finally cool the insole to allow the insole to flex thermoplastic material recovers its initial stiffness, thereby providing a custom anatomical insole.

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