JPH06296502A - Manufacture of rugged formed sheet - Google Patents

Abstract

PURPOSE:To achieve a simplification of the manufacturing process of a shoe sole and a reduction of the number of dies thereby used by combining a die-cut forming and a press forming. CONSTITUTION:An upper cutting die 11 is moved closer to a lower cutting die 12 to make gibbous parts 21 into indented parts 13. A blank sheet S is die-cut by the shearing motion caused by the scraping of the gibbous parts 21 against the indented parts 13 and the punched rugged patterns 3 are seized by the indented parts 13. The upper cutting die 11 is detached from the lower cutting die 12 to complete the die-cutting process. Subsequently, a base 26 overlaid with a material sheet 25 is placed below the upper cutting die 11. The upper cutting die 11 and the lower cutting die 12 are dram closer to each other to hold the material sheet 25 in-between and pressing rods 14 are extended downward to push the rugged patterns 3 out of the indented parts 13 and to press fix them onto the material sheet 25. After removing the upper cutting die, the sheet is further pressed by a flat die to make the adhesion perfect, thus the press forming process is completed and a rugged formed sheet is obtained.

Description

Detailed Description of the Invention

[0001]

[Object of the Invention]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a sheet-like member having a concavo-convex pattern provided for the purpose of preventing slippage, such as the sole of sports shoes. The present invention relates to a method for producing a concavo-convex shaped sheet, which is intended to reduce the number.

[0002]

BACKGROUND OF THE INVENTION In order to reduce the weight and improve the impact absorption of sports shoes used for various sports such as jogging, basketball and tennis, an outer sole, which is the lowest layer of the sole directly in contact with the ground, is used. Is made of solid rubber or high-density sponge, and the upper layer is constructed by stacking one or more sponges such as EVA (ethylene vinyl acetate) that are lightweight and have excellent cushioning properties, and try to make the shoe sole a multi-layer structure. Has been done.

However, although these solid rubbers and high-density sponges are relatively hard and exhibit excellent effects in terms of ground gripping force and abrasion resistance, on the other hand, they are heavy and light in weight. There were difficulties.

Therefore, in recent years, in addition to the improvement of the material for the sole, various molding methods for the sole have been devised. For example, a method in which a polyurethane resin film on a non-woven fabric sheet and a liquid polyurethane composition before forming non-slip projections are placed in a mold and heat-cured to integrally bond them (Japanese Patent Laid-Open No. 1-3106).
No. 01) is mentioned as an example. Further, even the applicant of the present invention, the stencil is placed in close contact with the non-woven fabric, the polyurethane elastomer containing a thickener is poured into the stencil,
A method of forming an embossed sheet by squeegeeing and then heat-curing to form an embossed sheet "Patent application 4"
No. 185922) or a method of forming an embossed sheet by injecting an embossing raw material into an intaglio created by sandblasting and then curing the embossing raw material while the base sheet is in close contact with the embossed sheet. Hei 4-343146) and so on.

However, all of these use liquid raw materials, which are poured into a molding die, a stencil plate or an intaglio plate and subsequently cured to form an uneven pattern. Therefore, it can be said that it is a preferable method for forming a concavo-convex pattern having a complicated shape, but on the other hand, it is possible to prevent the permeation into the base sheet and the adhesion between the stencil and the base sheet due to the use of the liquid raw material. It is necessary to take various countermeasures such as a device for increasing the amount or eliminating air mixed in when injecting the liquid raw material.

Further, when the intaglio and the stencil are prepared, a masking member or the like is required separately and various steps must be performed, which complicates the manufacturing process and the number of molds (the mold here is the above-mentioned molding mold). In addition to the above, all the guiding members required when molding a concave-convex pattern such as an intaglio, a stencil, or a masking member are used as a generic term, and the meaning of the mold in the following description in this specification means It was causing the problem of increasing the number).

Further, in principle, the mold, stencil, intaglio, etc. used in these manufacturing methods can be used for only one kind of uneven pattern (and even if the same uneven pattern is used, the height of the uneven pattern is high). However, it was not always preferable in terms of versatility, and there was room for further improvement in these points.

[0008]

[Technical Items Attempted to Develop] The present invention has been made in view of such a background, and a novel method has been achieved in which punching molding and press molding are combined to simplify the manufacturing process and reduce the number of molds. This is an attempt to develop a method for manufacturing a rough uneven sheet.

[0009]

[Constitution of the invention]

[Means for Achieving the Object] That is, the method for producing a concavo-convex shaped sheet according to the first invention of the present application is the method for producing a concavo-convex shaped sheet comprising a concavo-convex pattern of various shapes formed on a base sheet. The method is to form an upper die having a predetermined shape of concave portions formed in a pattern in advance and a convex portion that is provided at a position corresponding to the concave portion and that fits into the concave portion on its upper surface. Comprising a lower punching die, a blank sheet is inserted between the upper punching die and the lower punching die, and then the upper punching die and the lower punching die are brought close to each other to punch an uneven pattern from the blank sheet. The punching process and the upper punching die and the lower punching die are separated from each other while the punched concavo-convex pattern is left in the recessed portion, and the lower punching die is further retracted to the outside. Instead of the lower punching die, a base with a base sheet placed on the upper surface is made to face under the upper punching die, and then the two are brought into close contact with each other, and the pressing rod previously accommodated in the recessed portion and standing by is pushed downward. It is characterized in that it comprises a pressing molding step in which the uneven pattern is pressed and adhered to the base sheet.

The method for producing a concavo-convex shaped sheet according to a second invention of the present application is a method for producing a concavo-convex shaped sheet which is formed by forming concavo-convex patterns of various shapes on a base sheet. An upper punching die in which concave portions of a predetermined shape are formed in a pattern in advance, and a lower punch formed by forming a convex portion provided at a position corresponding to the concave portion and fitted to the concave portion on the upper surface thereof. A blank sheet is inserted between the upper punching die and the lower blanking die, and then the upper blanking die and the lower blanking die are brought close to each other to punch an uneven pattern from the blank sheet, punching molding Steps, and in such a state, the pressing rod that was previously housed in the recessed portion and was on standby was extended downward, whereby the concavo-convex pattern was formed into a convex shape in the lower die. Temporarily adhere to the top surface, and then the push rod is retracted into the recessed portion, and at the same time, the upper punching die and the lower punching die are separated from each other. Instead of the above, a flat mold is exposed above the lower punching die, and a base sheet is inserted between the lower punching die and the flat die, and the lower punching die and the flat die are brought into close contact with each other so that pressure bonding is performed. It is characterized in that it comprises a press molding step.

Furthermore, in addition to the requirements according to claim 1 or 2, the method for producing a concavo-convex molded sheet according to the third invention of the present application is characterized in that the blank sheet is a gel elastomer or a semi-cured polyurethane elastomer, or a main material thereof. It is characterized by being formed of a thermosetting resin or a photocurable resin as a component. Then, the constitutions of these inventions are used as means to achieve the above object.

[0012]

That is, according to the first invention of the present application,
By fitting the concave portions and the convex portions provided in the upper punching die and the lower punching die, respectively, the blank sheet inserted between them is sheared, and the concavo-convex pattern is punched from the blank sheet. The punched concavo-convex pattern remains in the recessed portion while being held by the recessed portion due to its viscosity or elastic deformation. Then, after the base on which the base sheet is placed is located below the upper die, the pressing rod is extended downward, thereby pushing out the concavo-convex pattern remaining in the recess downward from the recess, and further lowering the base Press and adhere to the sheet.

According to the second invention of the present application, punching is performed by the same operation as that of the first invention of the present application,
The uneven pattern remaining in the recess is pushed downward from the recess by extending the pressing rod downward, and the uneven pattern remaining in the recess is pushed down to the top surface of the convex part of the lower punching die located below it. Temporarily bond. Then, the flat die is positioned above the lower punching die, the base sheet is inserted between the lower punching die and this flat die, and then the flat die is pressed downward, and the unevenness pattern is pressed and adhered to the base sheet by the pressing force. .

Further, in the third invention according to the present application, the blank sheet is formed of gelled or semi-cured polyurethane elastomer or a thermosetting resin or a photocurable resin containing the polyurethane elastomer as a main component. This enables punching by fitting the concave portion and the convex portion, and ensures the gripped state by the concave portion. Further, when such a material is used, an excellent action can be expected in terms of ground gripping force and abrasion resistance, and it can also contribute to weight reduction of the uneven formed sheet.

[0015]

EXAMPLES A method for manufacturing a concavo-convex shaped sheet according to the present invention will be specifically described below with reference to the conceptual diagram shown in the drawings, taking the manufacturing process of the sole 2 of the sports shoe 1 as an example. In the description, first, the punching die 10 necessary for carrying out the method for producing a concavo-convex molded sheet of the present invention will be described, and then the method for producing a concavo-convex molded sheet according to the first invention of the present application will be first described. A method for manufacturing a concavo-convex molded sheet according to the second invention of the present application will be described as a second example.

The punching die 10 comprises an upper punching die 11 and a lower punching die 12
Among them, the upper punching die 11 is provided with a concave portion 13 having a predetermined shape corresponding to the concave-convex pattern 3 to be formed on the lower surface side thereof. Also, this recess 1
A contact portion 14a at the tip of the pressing rod 14 is accommodated in the inner portion 3 of the pressing rod 14. The contact portion 14a is normally located on the inner side of the upper side of the recessed portion 13 so that the pressing rod 14 can move when the pressing action is performed. It is configured to extend and project downward.

The driving means 15 for the pressing rod 14 is, as an example, an air or hydraulically driven cylinder 16.
Alternatively, the cam 17 may be used as shown in FIG. 5 (a), or the rack and pinion 18 may be used as shown in FIG. 5 (b), or as shown in FIG. 5 (c). By mechanical drive using screw drive 19, etc.,
As shown in FIG. 5D, various types such as an air type or hydraulic type driving means for driving the pressing rod 14 acting as a piston by forming an air or hydraulic system passage 20 in the upper punching die 11 itself. The driving means can be applied.

The pressing rod 14 is integrated with the upper punching die 11 as shown in FIGS. 2 to 5, and is formed separately from the upper punching die 11 as shown in FIG. In use, it can be attached to a necessary place as needed. Further, the contact portion 14a of the pressing rod 14
In addition to the planar shape shown in Fig. 7 (a),
As shown in FIG. 7B, a part thereof may be recessed in a stepped shape. By the way, when such a shape is adopted, the step-like uneven pattern 3 as shown in FIG.
Can be formed.

A lower punching die 12 is provided below the upper punching die 11 thus constructed. This bottom die 1
Reference numeral 2 serves to approach and separate from the upper die 11. It should be noted that such an action can be achieved by elevating and lowering one of the upper punching die 11 and the lower punching die 12; however, both the upper punching die 11 and the lower punching die 12 are provided with an elevating and lowering drive mechanism. May be driven in opposite directions.

A convex portion 21 is formed on the upper surface of the lower punching die 12 at a position corresponding to the concave portion 13 of the upper punching die 12. The convex portion 21 is fitted in the concave portion 13 and has a role of punching out a concave-convex pattern 3 having a predetermined shape from a blank sheet S described later by a shearing action by sliding friction with the inner wall surface of the concave portion 13. is there. The upper die 11 and the lower die 12 described above may be arranged upside down.

Next, a description will be given of a method for producing the unevenly formed sheet of the present invention using the punching die 10 thus constructed. The method for producing a concavo-convex molded sheet of the present invention comprises a punching molding step and a pressure molding step (this point is common to the first and second embodiments described below). ), In the following description, the manufacturing method of the present invention will be described by dividing these steps.

[I] First Embodiment i) Punching Molding Step First, as shown in FIG. 2A, the above-mentioned upper punching die 11 and lower punching die 12 are separated from each other, and the upper punching die 11 and the lower punching die are separated. The blank sheet S is inserted between the mold 12 and the mold 12. Incidentally, this blank sheet S is a raw material for the concavo-convex pattern 3, and is formed of, for example, a gelled or semi-cured polyurethane elastomer or a thermosetting resin or a photocurable resin containing the polyurethane elastomer as a main component. ing.

The term "photo-curing" of a photo-curable resin means that when it is irradiated with electromagnetic waves having high energy such as visible light, ultraviolet rays, X-rays and electron beams, it absorbs energy to cause crosslinking, curing and insolubilization. The term "light" is a general term for electromagnetic waves with high energy. Further, among the photocurable resins, it is particularly preferable to use an ultraviolet curable resin.

In selecting the ultraviolet curable resin, a transparent or translucent resin is used after curing so that the color of the pattern printed on the base sheet described later can be seen through, and in combination with the base sheet described later. Various colors can be applied, expecting a design effect due to the contrast. Moreover, since the uneven pattern 3 is used as the shoe sole 2 in the present invention, the hardened material has appropriate elasticity, and the shoe sole 2 has tensile strength, tear strength, abrasion resistance, and other physical properties that are required. An ultraviolet curable resin that can withstand the uneven pattern 3 is applied. In this case, in order to improve the tear strength, a filler such as short fibers may be mixed in the ultraviolet curable resin to the extent that curing is not hindered.

Next, as shown in FIG. 2B, the upper punching die 11
Then, the lower punching die 12 is moved closer to fit the convex portion 21 of the lower punching die 12 into the recessed portion 13 of the upper punching die 11. Then, the blank sheet S is punched by the shearing action caused by the sliding friction between the convex portion 21 and the concave portion 13, and the punched uneven pattern 3 is held in the concave portion 13 by its viscosity or elastic force. It stays in the recess 13.

Incidentally, the reason why the gel sheet or the semi-cured sheet is used as the blank sheet S is that the recessed and projected pattern 3 in the recess 13 is likely to remain. Then, as shown in FIG. 2C, the upper punching die 11 and the lower punching die 12 are separated from each other, whereby the punching molding step is completed.

Ii) Press-molding step Next, as shown in FIG. 3A, the base 26 on which the material sheet 25 is placed is positioned below the upper punching die 11, and then, as shown in FIG. The punching die 11 and the lower punching die 12 are brought close to each other to sandwich the material sheet 25, and the pressing rod 14 is extended downward to push out the concave-convex pattern 3 remaining in the concave portion 13 from the concave portion 13. Press on the material sheet 25.

The adhesion between the concave-convex pattern 3 and the material sheet 25 is performed only by such pressing, or in addition, an adhesive or a cross-linking reaction agent for the concave-convex pattern 3 is applied to the material sheet 25 in advance, and this is pressed. Adhesion can also be achieved by using together with pressing by the rod 14. As the base sheet 25, various materials such as rigid resin, rubber, and non-woven fabric, which are conventionally used as a base material for the outer sole of the athletic shoe 1, can be applied. When a non-woven fabric is applied as the base sheet 25, it may be either a thermoplastic fiber or a thermosetting fiber, and as an example, a backskin-like artificial leather such as Exaine (registered trademark) manufactured by Toray Industries, Inc. is applied. can do. By the way, since there are various colors such as yellow and orange in this Exeine (registered trademark), the shoe sole 2 can be given a design with a color contrast by making the uneven pattern 3 black.

In addition to the usual non-woven fabric sheet having tear strength, tensile strength and abrasion resistance, a thick film sheet or the like can be applied, and one having adhesiveness or one having a resin film coat Good. As a normal non-woven sheet, one obtained by self-bonding elastic long fibers such as urethane is suitable. In this case, for example, if a thick non-woven sheet having a thickness of about 1 cm is applied, it is possible to provide a shoe sole having excellent cushioning properties. The film sheet is the base sheet 2
When used as No. 5, it is difficult to express the contrast of the materials in design as compared with artificial leather or non-woven fabric, but the color contrast makes it possible to enhance the design.

When an ultraviolet curable resin is used as a material for forming the concavo-convex pattern 3, it is also possible to print a pattern design corresponding to the concavo-convex pattern 3 on the base sheet 25 as described above. . By doing so, by making the concave-convex pattern 3 transparent or semi-transparent, the color of the pattern design printed on the base sheet 25 can be recognized, and a design effect different from that of the embodiment can be obtained. Obtainable.

Also, various color contrasts can be selected between the color of the base sheet 25 and the color of the ink of the pattern design portion printed on the base sheet 25. For example, the base sheet 25 is black and the ink printed on the base sheet 25 is a bright color such as yellow or orange, or the base sheet 25 is red and the ink is blue. Color is the saturation,
It is also possible to establish a contrasting color relationship in which the colors of the inks are relatively conspicuous by making one of the lightness and the hue or a combination thereof different.

Further, as shown in FIG. 3C, the concave / convex pattern 3 adhered to the base sheet 25 in this manner is further illustrated.
As shown in FIG. 5, the upper punching die 11 can be retracted to position the flat die 27 above it, and further pressure can be applied by the flat die 27 to achieve complete adhesion. Then, when the uneven pattern 3 is completely cured by heating or irradiating the uneven pattern 3 in such a state, the uneven molded sheet 30 as shown in FIG. 1 is obtained, and the press molding process is completed. .

[II] Second Embodiment i) Punching and Molding Step Since this punching and molding step is common to the punching and molding step in the first embodiment, its explanation is omitted here. ii) Press-molding step The concavo-convex pattern 3 remaining in the recessed part 13 by the punching-molding step is pressed by the pressing rod 14 that extends as shown in FIG. It is pressed against the top surface 21a of the portion 21 and temporarily bonded.

Then, as shown in FIG. 4 (b), the pressing rod 14 is retreated toward the inner side of the recess 13 and at the same time,
The upper die 11 is separated from the lower die 12. Then, as shown in FIG. 4C, the upper punching die 11 is further retracted outward, and instead, a flat die 27 is positioned above the lower punching die 12 so that the lower punching die 12 and the flat die 27 are separated from each other. The base sheet 25 is inserted between them.

Next, as shown in FIG. 4D, the concavo-convex pattern 3 and the base sheet 25 are pressure-bonded to each other by the sandwiching action of the flat die 27 and the lower punching die 12. Then, in such a state, the concavo-convex pattern 3 is heated or irradiated with light to completely cure the concavo-convex pattern 3, so that the concavo-convex molded sheet 30 as shown in FIG. 1 is obtained, and the press molding step is completed.

[0036]

The method for producing a concavo-convex shaped sheet of the present invention has the above-mentioned constitution, and by having such constitution, the following effects are exhibited. First, in the first invention according to the present application, the concavo-convex pattern 3 punched out from the blank sheet S in the punching step is held by the concave portion 13, so that the adhesion position to the base sheet 25 is maintained. As it is, it is on standby for bonding with the base sheet 25 which is the next step.

Therefore, it is not necessary to set the position separately, and if the pressing rod 14 is extended downward as it is, the concave-convex pattern 3 is pressed and adhered to the base sheet 25.
Further, in the present invention, since the concavo-convex pattern 3 is formed by punching using the punching die 10, the above-mentioned problems occurring when the liquid raw material is injected into the shaping die or the like do not occur.

In the second invention according to the present application,
The concavo-convex pattern 3 remaining in the recess 13 is pressed by the pressing rod 1
4, the top surface 21 of the convex portion 21 of the lower punching die 12
It is temporarily bonded to a. Therefore, according to the present invention,
Similar to the first aspect of the invention, it is not necessary to perform any additional position setting, and the above-mentioned problems that occur when molding the concavo-convex pattern 3 from a liquid material do not occur.

Further, in the third invention according to the present application,
The blank sheet S is formed of a gelled or semi-cured polyurethane elastomer or a thermosetting resin or a photocurable resin containing the polyurethane elastomer as a main component. Therefore, it is possible to punch the concave-convex pattern 3 from the blank sheet S described above, and the blank sheet S in a completely cured state.
The adhesive force with the base sheet 25 is stronger than that in the case of using.

The blank sheet S in the gel or semi-cured state is more likely to adhere to the inner wall of the concave portion 13 as compared with that in the completely cured state, and the gripping state is improved. Further, if such a material is used, it exerts an excellent effect in terms of ground gripping force and abrasion resistance required when used as the sole 2 of the athletic shoe 1, and reduces the weight of the uneven molded sheet 30. Can also contribute.

The effects of these effects synergistically reduce the number of molds and simplify the manufacturing process. In addition, when the embodiment shown in FIG.
The versatility of is also improved.

[Brief description of drawings]

FIG. 1 is an exploded perspective view showing a state where a concavo-convex shaped sheet manufactured by a manufacturing method of the present invention is applied to a sole of an athletic shoe.

FIG. 2 is an explanatory view showing, step by step, a method for producing a concavo-convex shaped sheet of the present invention, and is a skeletal vertical sectional view showing the punching and forming step.

FIG. 3 is a skeletal vertical cross-sectional view showing the same press-molding step.

FIG. 4 is a skeletal vertical sectional view showing another embodiment of the same.

FIG. 5 is a skeletal vertical sectional view showing other various embodiments of the driving means of the pressing rod.

FIG. 6 is a vertical perspective view showing an embodiment in which an upper punching die and a pressing rod are separately configured.

7A and 7B are skeletal vertical cross-sectional views showing two examples in which the shape of the contact portion of the pressing rod is different.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Athletic shoes 2 Sole 3 Concavo-convex pattern 10 Cutting die 11 Upper punching die 12 Lower punching die 13 Recessed depression 14 Push rod 14a Abutting portion 15 Driving means 16 Cylinder 17 Cam 18 Rack and pinion 19 Screw drive 20 System path 21 Convex Part 21a Top surface 25 Base sheet 26 Base 27 Flat 30 Concavo-convex molded sheet S Blank sheet

Claims (3)

[Claims] 1. A method of manufacturing a concavo-convex shaped sheet, which comprises forming a concavo-convex pattern of various shapes on a base sheet, wherein the manufacturing method is pre-punched in which concave portions of a predetermined shape are formed in a pattern in advance. A mold and a lower punching die which is provided at a position corresponding to the concave portion and has a convex portion which fits in the concave portion and is formed on the upper surface thereof, and between the upper punching die and the lower punching die. Blank sheet is inserted into the blank sheet, and then the upper punching die and the lower punching die are brought close to each other to punch an uneven pattern from the blank sheet, in a punching forming step, and the punched uneven pattern is left in the recessed portion. The upper punching die and the lower punching die are separated from each other as they are, and the lower punching die is further retreated to the outside, and a base sheet is placed on the upper surface below the upper punching die instead of the lower punching die. The base is exposed, and then the two are brought into close contact with each other, and the pressing rod that has been previously stored in the recessed portion and is on standby is extended downward, whereby the concavo-convex pattern is press-bonded to the base sheet. A method for producing a concavo-convex shaped sheet, comprising the steps of: 2. A method for manufacturing a concavo-convex shaped sheet, which comprises forming a concavo-convex pattern of various shapes on a base sheet, wherein the manufacturing method is pre-punched in which concave portions of a predetermined shape are formed in a pattern in advance. A mold and a lower punching die which is provided at a position corresponding to the concave portion and has a convex portion which fits in the concave portion and is formed on the upper surface thereof, and between the upper punching die and the lower punching die. The blank sheet is inserted into the blank sheet, and then the upper die and the lower die are brought closer to each other to punch the uneven pattern from the blank sheet. The pressing rod that had been used is extended downward, whereby the concavo-convex pattern is temporarily adhered to the top surface of the convex portion of the lower die, and then the pressing rod is retracted into the concave portion. At the same time, the upper punching die and the lower punching die are separated from each other, and further, the lower punching die is retreated outward, and a flat die is made to face above the lower punching die instead of the upper punching die. A concavo-convex molded sheet characterized by comprising a press molding step in which a base sheet is inserted between the lower punching die and the flat die, and the lower punching die and the flat die are brought into close contact with each other by pressure bonding. Manufacturing method. 3. The blank sheet is formed of a gel or semi-cured polyurethane elastomer or a thermosetting resin or a photocurable resin containing the polyurethane elastomer as a main component. A method for manufacturing a concavo-convex molded sheet.