JP2007144002A - Method of manufacturing insole having embossing on surface - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method capable of easily and inexpensively obtaining an insole which has a cushioning property and also can ensure sufficient air permeability between the insole and the sole of a foot. <P>SOLUTION: A layered product 11, which is composed of a base material 13 consisting of a polyolefin-based resin foamed body, an adhesive 15, and a surface material 17 composed of an open cell polyurethane foamed body formed with an embossing 18 thereon, is softened by heating, and is pressed with a shaping die 21 whose mold surface 26 facing the embossed surface is composed of a foamed body having a hardness of 9-500 N. Thus, the layered product 11 is shaped into an insole shape without crushing the embossing 18 on its surface, thereby obtaining the insole having the air permeability and the cushioning property. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing an insole having a texture on its surface.

  The insole (shoe insole) preferably has an appropriate cushioning property and the foot is not easily stuffy in the shoe. Furthermore, the material of the insole is preferably one that can be easily shaped into an insole shape. Therefore, it is conceivable that the open-cell polyurethane foam is softened by heating and shaped into an insole shape by pressing to form an insole.

  However, even if the insole is composed of an open-cell polyurethane foam, the insole is smooth because the contact surface with the sole of the foot is smooth, and the insole is in a horizontal direction on the contact surface with the sole of the foot. Since no air passage was formed, the air permeability was insufficient.

  An insole with a double raschel mesh layer laminated on the surface of the cushion material to improve air permeability has also been proposed, but the double raschel mesh layer is pressed and crushed by the sole of the foot during use. It is difficult to say that the air permeability is sufficient because a sufficient horizontal air passage cannot be secured on the contact surface.

Japanese Patent Laid-Open No. 10-295409

  The present invention has been made in view of the above points, and is a manufacturing method that can easily and inexpensively provide an insole that has cushioning properties and that can ensure sufficient air permeability between the back surface of the foot. For the purpose of provision.

  Invention of Claim 1 heat-softens the laminated body comprised by the base material which consists of a polyolefin-type resin foam, an adhesive agent, and the surface material which consists of an open-cell polyurethane foam in which the embossing was formed on the surface, The present invention relates to a method for producing an insole having a wrinkle on a surface, characterized by pressing and shaping with a shaping mold composed of a foam having a hardness of 9 to 500 N on a mold surface facing the surface on which the wrinkle is formed. .

  According to a second aspect of the present invention, in the first aspect, the foam is made of a polyurethane foam.

  According to the present invention, when pressing and shaping a heat-softened laminate, the surface of the laminate is pressed with a foam having a hardness of 9 to 500 N, so that the surface is difficult to be crushed and the surface is Can be obtained easily and inexpensively. In addition, since the obtained insole has wrinkles on the surface that comes into contact with the sole of the foot, a horizontal air passage is secured on the contact surface with the sole of the foot, and the surface material is made of a breathable polyurethane foam. Therefore, a ventilation path is secured also in the vertical direction, and it is possible to effectively prevent foot stuffiness. Furthermore, the insole manufactured by the manufacturing method of the present invention has a cushioning property suitable for a foot by a base material made of a polyolefin resin foam and a surface material made of an open-cell polyurethane foam having a surface formed with wrinkles. Demonstrate.

  Hereinafter, embodiments of the present invention will be described in detail. 1 is a perspective view of an embodiment of an insole manufactured by the manufacturing method of the present invention, FIG. 2 is an enlarged cross-sectional view of FIG. 1 2-2, and FIG. 3 is a laminate in an embodiment of the manufacturing method of the present invention. FIG.

  The insole 10 shown in FIGS. 1 and 2 is manufactured by the manufacturing method of the present invention. The insole 10 is a continuous base material 13 made of a polyolefin resin foam, an adhesive 15, and a texture 18 formed on the surface. A laminate 11 composed of a surface material 17 made of cellular polyurethane foam is shaped by pressing after being softened by heating.

The laminated body 11 which consists of the said base material 13, the adhesive agent 15, and the surface material 17 is demonstrated. As the polyolefin resin foam constituting the substrate 13, a known polyolefin resin foam can be used. For example, polyethylene, ethylene-vinyl acetate copolymer, polypropylene, polytetrafluoroethylene, ethylene-propylene copolymer Examples thereof include foams of polyolefin resins such as coalescence, poly-4-methyl-1-pentene, polyvinyl chloride, polyvinylidene chloride, polyvinylidene fluoride, tetrafluoroethylene, and ethylene copolymer. In addition, the manufacturing method of the said polyolefin resin foam can be performed with the well-known foaming method which adds a crosslinking agent, a foaming agent, a foaming adjuvant, etc. to an olefin resin, and mix-kneads and foams. Further, either one-stage foaming or two-stage foaming may be used. The density of the polyolefin resin foam constituting the substrate 13 (density before pressing the laminate 11) is 25 to 200 kg / m ³ , preferably 50 to 90 kg / m ³ .

  As the adhesive 15, an organic solvent-based adhesive is preferable. Examples of the organic solvent-based adhesive include phenol-based adhesives such as novolac-type phenol resin-based adhesives or phenol resin-based adhesives containing a resol-type phenol resin and an epoxy-modified phenol resin, and rubbers such as unvulcanized NBR. Examples thereof include a phenol resin-based adhesive containing a composition component. In addition, styrene / butadiene copolymer rubber / organic solvent-based adhesives that have been widely used can be cited. The styrene / butadiene copolymer may be either a random copolymer or a block copolymer. Furthermore, as long as the adhesive strength of the styrene-butadiene copolymer rubber is not impaired, a small proportion of comonomer, for example, an acrylic unsaturated monomer such as acrylic acid, methacrylic acid, methyl methacrylate, acrylonitrile, etc. may be copolymerized. Good. Styrene-butadiene copolymers may be used alone or in combination of two or more. As the organic solvent blended in the adhesive, an organic solvent that can dissolve the styrene / butadiene copolymer rubber and does not contain halogen is used. Specific examples of the organic solvent include alicyclic hydrocarbons such as cyclohexane and cyclooctane, aliphatic hydrocarbons such as n-hexane and n-heptane, aromatic hydrocarbons such as toluene and benzene, ketones such as acetone and methyl ethyl ketone. , Ethers such as tetrahydrofuran, esters such as methyl acetate and ethyl acetate, dimethyl sulfoxide, dimethylformamide and the like. These organic solvents can be used alone or in combination of two or more. The adhesive 15 is applied to one or both of the adhesive surfaces of the base material 13 and the surface material 17.

As the open-cell polyurethane foam constituting the surface material 17, various foams such as a soft slab and a molded product can be used. In particular, a foam produced by a known mechanical floss method is preferable because it is suitable for cushioning and is preferably a low foamed product in consideration of durability, hardness and the like. The mechanical floss method is a method of forming a polyurethane foam by mixing an inert gas in a polyurethane raw material with a mixer and discharging the polyurethane raw material mixed with the inert gas without substantially foaming. The density of the open-cell polyurethane foam (density before pressing the laminate 11) is 0.15 to 0.8 g / cm ³ , more preferably 0.20 to 0.48 g / cm ³ , and still more preferably 0.00. 20 to 0.32 g / cm ³ . The embossed surface 18 is composed of fine irregularities, and a polyurethane raw material mixed with an inert gas by the mechanical flossing method is discharged onto a release paper with an embossed surface, adjusted for thickness, and then cured by heating. It is obtained by. In addition, the open-cell polyurethane foam constituting the skin material 17 refers to a polyurethane foam in which the ratio of open cells is higher than the ratio of closed cells, and does not indicate that all the bubbles are composed of open cells. Absent. Generally, a flexible polyurethane foam is known as an open-cell polyurethane foam.

  The insole is manufactured by heating and softening the laminate 11 and then pressing and shaping with a shaping die 21 shown in FIG.

  The shaping mold 21 includes a lower mold 23 and an upper mold 25. The lower mold 23 is made of a hard material such as metal or resin, and a concave mold surface 24 is formed on the surface facing the mold surface 26 of the upper mold 25 to match the insole shape. On the lower mold surface 24, the base material 13 side of the laminate 11 is disposed. On the other hand, the upper mold 25 includes a convex mold surface 26 that fits into the mold surface 24 of the lower mold 23. The mold surface 26 of the upper mold 25 is a mold surface that faces the emboss 18 on the surface of the surface material 17 when the laminate 11 is pressed, and has a lower hardness than the mold surface 24 of the lower mold 23. It consists of As the foam constituting the mold surface 26 of the upper mold 25, the laminated body 11 is pressed so as not to crush the texture 18 when the heat-softened laminated body 11 is pressed by the lower mold 23 and the upper mold 25. No. 11 is hard enough to be shaped, and a foam having a hardness of 9 to 500 N (based on JIS K6400-2: 2004 D method), more preferably a hardness of 186 to 246 N is preferable. The material is preferably polyurethane foam. When the hardness of the foam constituting the mold surface 26 is close to 9N, the amount of compression at the time of pressing is increased and pressing is performed with high hardness. Further, when the hardness of the foam constituting the mold surface 26 is close to 500 N, the pressing is performed to the extent that it is pressed without being compressed at the time of pressing. The foam of the mold surface 26 may be adjusted to the hardness by compression.

  The preferred thickness of the laminate 11 before pressing is 3 to 15 mm, more preferably 5 to 11 mm for the base material 13, and 1 to 5 mm, more preferably 1.5 to 3 mm for the surface material 17. The heating temperature of the laminate 11 is a temperature at which the laminate 11 can be brought into a softened state that can be shaped by pressing. Since the base material 13 made of the polyolefin resin foam has the lowest softening temperature among the members constituting the laminate 11, the heating temperature of the laminate 11 is the softening temperature of the polyolefin resin foam. Usually, it is 70-160 degreeC, Preferably it is 110-140 degreeC. The heating time is 1 minute to 5 minutes, preferably 1 to 2 minutes. The laminated body 11 can be heated by an appropriate method such as housing the laminated body 11 in a heating furnace or blowing hot air on the laminated body 11.

Open-cell polyurethane foam having a thickness of 2 mm and a density of 0.27 g / cm ³ as a surface material (wrinkled on the surface, surface texture of the textured surface 23 μm, product name: Polon (registered trademark) # 4000, manufactured by Inoac Corporation) A polyolefin resin foam having a thickness of 8 mm (density 70 kg / m ³ , product name: PE Lite A-8, manufactured by Inoac Corporation) was used as a base material, and the back surface (surface without wrinkles) and base A solvent-based SBR adhesive (product name: G-99Z, manufactured by Konishi Co., Ltd.) was spray-coated on both of the adhesive surfaces of the material, and then the surface material and the substrate were laminated with a laminator and adhered to obtain a laminate .

The laminate was cut into a length of 80 × 160 mm and punched into a predetermined foot shape with a Thomson blade. And the laminated body after stamping was accommodated in the heating furnace, and it heated at 130 degreeC for 90 second, and was softened. The heat-softened laminate was quickly pressed with a room temperature shaping mold. The shaping mold shown in FIG. 3 is used, and the upper mold is a cut-out product of the body portion made of aluminum and the mold surface made of soft slab polyurethane foam (density 75 kg / m ³ , tensile strength 98 kPa, hardness 210 N, product name : SP-80, manufactured by Inoac Corporation), while the lower mold is made of aluminum including the mold surface. The base material side of the laminate is placed on the lower mold surface so that the surface texture is opposed to the upper mold surface, and the upper mold is pressed against the laminate in that state and pressed for 1 minute. It was shaped by.

  The shaped product was demolded to obtain an insole. In the obtained insole, wrinkles remained clearly on the sole contact surface. Moreover, when the surface contact degree of the sole contact surface was measured with a VH-7000 microscope, 200 times, manufactured by KEYENCE, it was 23 μm, and it was confirmed that the surface material was not crushed by the press.

  In the above embodiment, the upper mold surface is made of foam, but the lower mold surface is made of foam and the upper mold surface is made of resin or metal. Alternatively, the insole may be manufactured by placing the layered product on the surface of the layered product and pressing the substrate side of the layered product with the upper mold surface.

It is a perspective view of one embodiment of the insole manufactured by the manufacturing method of the present invention. It is 2-2 expanded sectional drawing of FIG. It is sectional drawing of the laminated body and shaping tool in one Embodiment of the manufacturing method of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Insole 11 Laminated body 13 Base material 15 Adhesive 17 Surface material 18 Wrinkle

Claims (2)

A laminate composed of a base material made of a polyolefin resin foam, an adhesive, and a surface material made of an open-cell polyurethane foam having a surface formed with wrinkles,
Soften by heating,
A method for producing an insole having a wrinkle on a surface, characterized by pressing and shaping with a shaping mold composed of a foam having a hardness of 9 to 500 N on a mold surface facing the surface on which the wrinkle is formed. The method for producing an insole having a texture on a surface according to claim 1, wherein the foam is made of a polyurethane foam.

Images