KR20240032329A - Manufacturing method of products with three-dimensional molded article integrated with fabric or textile - Google Patents

Abstract

The present invention includes the steps of preparing a thermoplastic synthetic resin molding material mixed with a foaming agent and excluding a crosslinking agent; Preparing the lower plate mold (10) and the first and second upper plate molds (20, 30), respectively; Manufacturing a linearly formed body to have a volume smaller than the volume of the molding space 13 of the lower plate mold 10; Placing the linear body on the other side of the lower plate mold (10) and joining the first upper plate mold (20) to the lower plate mold (10) to first expand and cool the linear molded body in a pressurized state; Removing the overflowed portion beyond the outer edge 11 of the lower plate mold 10 and the first outer edge 21 of the first upper plate mold 20 in the first foam molded body 120; After placing the fabric 160 with one side facing the other side of the first foam molded body 120, the second top plate mold 30 is placed against the other side of the fabric 160 with one side facing the other side of the fabric 160. Providing a method of manufacturing a product in which a three-dimensional foam molded product and a fabric are integrated, including the step of secondary foaming and cooling molding of the primary foam 120 in a pressurized state by combining the mold 30 with the lower plate mold 10. do.

Description

{Manufacturing method of products with three-dimensional molded article integrated with fabric or textile}

The present invention relates to a method of manufacturing a product in which a three-dimensional foam molding and a fabric are integrated. More specifically, it is possible to manufacture a product in which a molded product having various three-dimensional shapes can maintain a stable bond with the fabric for a long time, as well as the product itself. It is possible to reduce the weight or implement three-dimensional foam moldings to have different densities for each part, and furthermore, it is possible to fundamentally prevent the phenomenon of defective products being manufactured as the molding material itself overflows along the boundary line of the molding space during the foam molding process. It relates to a method of manufacturing a product in which a three-dimensional foam molding and fabric are integrated.

Products such as shoes and clothing, as well as bags and hats, are generally made using fabrics such as natural fabrics or artificial fabrics. These products protect the product itself and the user wearing it, and furthermore provide functional aspects. Moldings of various shapes or shapes are attached as a way to add value and make the product stand out.

The most common method of attaching molded products with various shapes or shapes to fabric is sewing. Due to its nature, sewing must be done manually, so productivity varies depending on the worker's skill level, and if the molded product itself is made of a complex shape, sewing can be done manually. There was a problem that not only did productivity decrease, but the defect rate increased. A suggested alternative to this is the use of adhesive or adhesive film.

The former has the advantage of being easy to work with and independent of the worker's skill level, but has the disadvantage of being less durable and causing the molded product to separate from the fabric when the product is used for a long time or washed. In comparison, the latter, which uses an adhesive film such as a TPU film, has the advantage of maintaining a stable bond for a long time in that it melts the adhesive film during the heating process to integrate the molded product and the fabric.

However, in order to bond the molded product to the fabric using an adhesive film, the molded product must be heated while being strongly pressed together with the fabric. In this case, there is a problem that the shape or shape of the molded product is damaged or deformed due to the transmitted heat. In addition, when the molded product is heated in a pressurized state, a so-called overflow phenomenon occurs, in which some of the molten material overflows to the outside beyond the boundary formed in the molding space of the mold.

If overflow of the molten material occurs during the pressurization and heating process, there is a problem that immediately leads to product defects. Therefore, molded products to which this method can be applied generally have the disadvantage of being limited to a flat shape that can minimize damage or deformation to the shape of the molded product itself even when heat is transferred in a pressurized state by a mold.

Meanwhile, in related industries, liquid PU is used as a method of forming molded products with various three-dimensional shapes on one side of the fabric. This method, called casting PU, involves putting liquid PU into the molding space of a mold with an arbitrary shape, scraping off excess liquid PU that exceeds the volume of the molding space, then placing the fabric in the mold, pressurizing, and cooling. It is done through a process.

In this case, some of the liquid material is impregnated into the surface layer of the fabric, and the molded product and the fabric are integrated. In other words, this method has the advantage of not only being able to express the molded product three-dimensionally using a mold, but also combining the molded product with the fabric without using a separate adhesive means between the molded product and the fabric. However, this method has the inconvenience of having to manually remove excess material that exceeds the volume of the molding space.

In addition, liquid PU had the disadvantage of being extremely limited in the size and shape of the molded product in that it was difficult to make the product itself lightweight due to its high density. In addition, in this method, since the molded product itself is foam molded while filling the molding space of the mold evenly (maintaining the same density for each part), it was very difficult to form different densities or physical properties for each part in the final product. As an alternative to this casting PU method, the applicant has proposed Republic of Korea Patent No. 1401489 and Republic of Korea Patent No. 1263209.

In these technologies, the molding space of the mold is excessively filled with molding material, then the molds are joined, the molded mold is heated, the molded material reaches a melted state, the molded mold is opened, and excess material outside the molding space is removed. By placing the fabric and combining the material and fabric, it has a structural feature that allows the fabric to be integrated into the molded product in the shape of the mold's molding space, similar to the casting PU method.

However, both of these technologies are the same as the casting PU method described above in that they necessarily involve a step of heating the mold in which excess molding material is filled and combined, and then removing all excess material remaining outside the molding space. There was quite a bit of work hassle. In addition, in the former case, when excess material outside the molding space is removed, the mold is joined with the fabric placed, and then the product is manufactured through cooling molding. As a result, the product itself is damaged due to the molding having the same high density as casting PU. It is difficult to reduce the weight, and the size or shape of the molded product that can be expressed is extremely limited.

In contrast, the latter is comparable to the former in that when excess material outside the molding space is removed, the mold is joined with the fabric placed, the materials are crosslinked by heating for a certain period of time, and then the mold is rapidly opened and foam molded. It is possible to reduce the weight of the product to some extent. However, given that the product is manufactured by foam molding following rapid opening of the mold, not only is it impossible to accurately control the dimensional precision of the molded product that makes up the final product, but the fabric itself must also be stretched depending on the foam rate of the material. Therefore, there is a disadvantage that the available fabrics are limited.

Republic of Korea Patent Publication No. 2000-0061444 Republic of Korea Patent No. 1401489 Republic of Korea Patent No. 1263209

The present invention was proposed to improve the problems of the prior art, and the purpose of the present invention is to provide foam moldings with various three-dimensional shapes that correspond 1:1 to the molding space of the mold, regardless of the type or elasticity of the fabric. It is possible to maintain a stable bond with the fabric for a long time, and furthermore, the foam molding integrated with the fabric is foamed with various densities for each part, making it possible to manufacture lightweight products, as well as preventing overflow of the molding material along the boundary line of the molding space during the molding process. The aim is to propose a method for manufacturing three-dimensional products that do not cause flow phenomenon.

In order to achieve this object, the present invention includes the steps of preparing a thermoplastic synthetic resin molding material mixed with a foaming agent and excluding a crosslinking agent; It has an outer border (11) on the other side having the same shape and area as the outer edge of the product, and a molding space (13) made of the same shape as the three-dimensional shape protruding to the outside of the product is provided inside the outer border (11). The lower plate mold (10) has a first outer border (21) on one side, which has the same shape and area as the outer border (11) of the lower plate mold (10), and has a lower plate mold (10) inside the first outer border (21). ), a first top plate mold 20 provided with a protruding end 23 that corresponds to the shape of the molding space 13 and has a volume smaller than the volume of the molding space 13, and a second top plate with one side having a flat surface. Preparing each mold 30; Manufacturing a linear formed body using the prepared molding material so that the area located inside the outer edge 11 of the lower plate mold 10 has a volume smaller than the volume of the molding space 13 of the lower plate mold 10; One side of the linear body is placed on the other side of the lower plate mold 10 in which the molding space 13 is formed, and then the first upper plate mold 20 is molded in a state where one side faces the other side of the linear body 110. A step of pressing the upper plate mold (20) by joining it with the lower plate mold (10); Heat is supplied to the lower plate mold 10 and the first upper plate mold 20, which are pressed together, and the linear formed body is formed into the molding space 13 of the lower plate mold 10 and the protruding end 23 of the first upper plate mold 20. ) Primary foaming step of the preformed body, which is expanded and molded into each three-dimensional shape; Blocking heat transfer to the lower plate mold (10) and the first upper plate mold (20), then forming the pressed lower plate mold (10) and the first upper plate mold (20) by primary cooling; Releasing the pressure and opening the first upper plate mold (20) that was joined with the lower plate mold (10); removing the overflowed portion beyond the outer edge 11 of the lower plate mold 10 and the first outer edge 21 of the first upper plate mold 20 in the foamed primary foam molded body 120; In a state where the primary foam molded body 120 with the overflow area removed is placed in the lower plate mold 10, it has the same shape and area as the first outer border 21 of the first upper plate mold 20 and is formed on the first upper plate mold 20. One side of the fabric 160 is placed against the other side of the primary foam molded body 120, which is foamed and molded in the shape of the protruding end 23 of the mold 20, and then one side of the second upper plate mold 30 is placed against the other side of the first foam molded body 120. A step of pressing the second upper plate mold (30) into the lower plate mold (10) while facing the other side of the provisional fabric (160); Heat is supplied to the lower plate mold (10) and the second upper plate mold (30), which are pressed together, to have an outer border of the same shape and area as the outer border (11) of the lower sheet mold (10), but one surface thereof is It is molded again into the shape of the molding space 13 of the lower plate mold 10, and the other surface of the primary foam molded body 120 molded into the shape of the protruding end 23 of the first upper plate mold 20 is expanded and the fabric ( 160) and a secondary foaming step of integration; Blocking heat transfer to the lower plate mold (10) and the second upper plate mold (30), then forming the pressurized lower plate mold (10) and the second upper plate mold (30) by secondary cooling; By releasing the pressure and opening the second upper plate mold (30) that was joined with the lower plate mold (10), the other side is expanded and molded into the shape of the other side of the second upper plate mold (30) and integrated with the fabric (160). The technical feature is that it includes the step of recovering the secondary foam molded body 130, whose one side portion has been molded into the shape of the molding space 13 of the lower plate mold 10.

The protruding end 23 of the first upper plate mold 20 can be formed in the molding space 13 of the lower plate mold 10 at a point where the primary foam molded body 120 has different densities and requires foaming. .

The lower plate mold 10 is composed of an auxiliary lower plate mold combined with the first upper plate mold 20 and a main lower plate mold combined with the second upper plate mold 30, and the main molding space formed in the main lower plate mold is the lower plate mold. It has the same shape and shape as the molding space 13 of the mold 10, and the auxiliary molding space formed in the auxiliary lower plate mold has the same shape and shape as the molding space 13 formed in the main lower plate mold. The volume may be made smaller than the volume of the main forming space.

The linear formed body has a shape corresponding to the outer edge 11 of the lower plate mold 10, and the portion located inside the outer border 11 of the lower plate mold 10 is located in the molding space 13 of the lower plate mold 10. ), or is made of an injection molded product 111 with a volume smaller than the volume of ), or has an area that can be sealed to the outer edge of the outer edge 11 in the lower plate mold 10, but is limited to the molding space of the lower plate mold 10. It may be made of a molded sheet 116 whose thickness is adjusted to have a volume smaller than the volume of (13).

The combined mold of the first upper plate mold 20 and the lower plate mold 10 is a hot melt film in which the linear formed body is placed inside the outer edge 11 of the lower plate mold 10 and then a release paper 141 is provided on the other side. One side of (140) is placed so as to face the other side of the linear formed body, and one side of the first upper plate mold (20) faces the release paper (141). It can be molded into the lower plate mold (10). .

Before placing the linear molded body inside the outer edge 11 of the lower plate mold 10, prepare a synthetic resin film 150 and place it so that one side faces one side of the lower plate mold 10, and the line The molded body may be placed on the other side of the synthetic resin film 140.

At this time, a printing layer having an arbitrary shape or color may be formed on the other side of the synthetic resin film 150.

One surface of the first upper plate mold 20 has the same flat surface as that of the second upper plate mold 30; In the first foaming step of the linear formed body, heat is supplied to the lower plate mold 10 and the first upper plate mold 20, which are pressed together, to form the linear formed body into the molding space 13 of the lower plate mold 10 and the first upper plate mold 10. This can be done through the process of expanding and molding into a shape between the flat surfaces of the upper plate mold 20.

At this time, in the step of joining the second upper plate mold 30 to the lower plate mold 10, the fabric 160 placed on the other side of the first foam molded body 120 may be made of a fabric having a mesh network structure.

In the present invention, a linear molded body manufactured using a molding material containing a foaming agent and excluding a crosslinking agent is placed together with a fabric inside a mold with a molding space of an arbitrary shape, and then foamed and molded through a pressurizing and heating process to form a linear molded body. A product that allows foam moldings with various three-dimensional shapes to maintain a stable bond with the fabric for a long time, regardless of the type or elasticity of the fabric, by providing a method of molding in a 1:1 correspondence with the shape of the molding space and simultaneously integrating it with the fabric. manufacturing is possible.

In addition, in the present invention, when foam molding a linear body manufactured using a molding material, surplus space is provided to a specific portion of the molding space formed in the mold, so that the expansion of the linear body can proceed in a specific direction, Not only is it possible to lighten the product itself, but the three-dimensional foam molding integrated with the fabric can be implemented to have different densities for each part. Furthermore, during the foam molding process, the linear mold itself overflows along the boundary line of the molding space, resulting in defective products. It is possible to fundamentally prevent the manufacturing phenomenon.

1A to 5B are schematic diagrams showing a method of manufacturing a product according to an embodiment of the present invention.
6 is a schematic configuration diagram of a product manufactured according to the present invention.
7 to 8B are schematic diagrams showing a product manufacturing method according to another embodiment of the present invention.
9A to 9C are photographs of a lower plate mold and first and second upper plate molds for manufacturing a shoe upper as an example according to the present invention.
FIGS. 10A to 10G are photographs showing steps in manufacturing shoe uppers using the molds of FIGS. 9A to 9C, respectively.
11 is a photograph of a shoe upper manufactured by another embodiment according to the present invention.

Preferred embodiments according to the present invention will be examined in detail with reference to the accompanying drawings as follows. In describing the embodiments of the present invention in detail, there is no direct relationship with the technical features of the present invention, or general knowledge in the technical field to which the present invention belongs. Detailed explanations will be omitted for matters that are obvious to those with knowledge.

The present invention relates to a method of manufacturing a product in which a three-dimensional foam molding and a fabric are integrated, comprising steps of preparing molding materials and a mold, manufacturing a linear molded body, primary foaming and cooling molding of the linear molded body, and primary foam molding. It has the characteristic of including secondary foaming and cooling molding steps. Below we look at each of these steps in detail.

First, prepare the molding materials. Molding materials are made by mixing thermoplastic synthetic resins such as TPU, TPE, TPEE, etc. as main materials with a foaming agent, and at this time, cross-linking agents are excluded. The reason for not adding a cross-linking agent to the molding material in the present invention is to sequentially apply heat and mold it into a molding space shape that corresponds 1:1 to the shape of the final product (hereinafter referred to as product). The mixing ratio of the foaming agent may vary depending on the degree of lightweighting (density of each part) of the final product.

Next, prepare the mold. In the present invention, the mold is a means of foam molding the molding material into the shape of the product and simultaneously integrating the foam molding with the fabric, and includes a lower plate mold 10 and first and second upper plate molds 20, as shown in FIGS. 1A to 1C, respectively. , 30).

An outer border 11 and a molding space 13 are formed on the other side of the lower plate mold 10. At this time, it is preferable that the outer edge 11 of the lower plate mold 10 has the same shape and area as the outer edge of the product. In addition, it is desirable that the molding space 13 has the same shape as the three-dimensional shape that is exposed and protrudes from the outside of the product. Reference numeral 15 is a pressurized end.

That is, in the lower plate mold 10, the outer border 11 is configured to correspond 1:1 with the area forming the outer edge of the product, and the molding space 13 is configured to correspond 1:1 with the three-dimensional shape of the product. do. In the drawing, the configuration of the outer border 11 forming a single closed curve and the molding space 13 forming a single three-dimensional shape are disclosed, but this is only an example and a plurality of closed curves and a plurality of molding spaces can be provided. am.

The first upper plate mold 20 is a means of implementing the first foam molded body together with the lower plate mold 10, and a first outer border 21 and a protruding end 23 are formed on one surface thereof. At this time, it is preferable that the first outer border 21 has the same shape and area as the outer border 11 of the lower plate mold 10. Reference numeral 25 is a pressure groove formed along the outside of the first outer edge 11 to correspond to the pressure end 15.

The protruding end 23 forms a molding surface and is formed inside the first outer border 21, and is configured to correspond to the shape of the molding space 13 of the lower plate mold 10. At this time, it is preferable that the volume of the protruding end 23 of the first upper plate mold 20 is smaller than the volume of the molding space 13 formed in the lower plate mold 10.

That is, if the molding space 13 of the lower plate mold 10 and the protruding end 23 of the first upper plate mold 20 are formed as shown in the drawing, the vertical height of the protruding end 23 of the first upper plate mold 20 h is configured to be smaller than the depth d of the molding space 13 of the lower plate mold 10. The reason the present invention configures the volume of the protruding end 23 of the first upper plate mold 20 to be smaller than the volume of the molding space 13 of the lower plate mold 10 is to secure extra foaming space.

The second upper plate mold 30, along with the lower plate mold 10, is a means of implementing a secondary foam molding integrated with the fabric, and it is desirable that one side of the second upper plate mold 30 is made of a flat surface. In this case, the molding space formed by combining the lower plate mold 10 and the second upper plate mold 30 is larger than the molding space formed by combining the lower plate mold 10 and the first upper plate mold 20, and this molding The volume difference in space becomes extra foam space.

At this time, in the present invention, the protruding end 23 protruding inside the first outer border 21 of the first upper plate mold 20 is located in the molding space 13 of the lower plate mold 10 and forms a primary foam molded body to be described later. (120) suggests a case where foaming is required at different densities. That is, the drawing shows a case where the molding space 13 and the protruding end 23 are configured to be upside down, but unlike this, the protruding end 23 has a plurality of irregularities regardless of the shape of the molding space 13. It may be made up of various shapes. However, it is clear that this may vary depending on the specific shape of the product to be ultimately implemented.

Meanwhile, the present invention does not exclude the case where the lower plate mold 10 to be prepared is made of an auxiliary lower plate mold joined with the first upper plate mold 20 and a main lower plate mold combined with the second upper plate mold 30. At this time, a main molding space is formed in the main lower plate mold, and an auxiliary molding space is formed in the auxiliary lower plate mold.

The main forming space of the main lower plate mold may have the same configuration as the forming space 13 of the lower plate mold 10 described above. Additionally, the auxiliary molding space of the auxiliary lower plate mold preferably has the same shape as the main molding space, but has a smaller volume than the main molding space. This is to make the total molding space when the first upper plate mold 20 and the auxiliary lower plate mold are combined to be smaller than the total molding space when the second upper plate mold 30 and the main lower plate mold are combined.

Once the mold is prepared, the linear body is manufactured using the molding material. In the present invention, the linear body can be manufactured by injection molding the prepared molding material, T-die extrusion sheet molding, or 3D printing. When the linear molded body is made of an injection molded product 111 as shown in FIG. 2, it has a shape corresponding to the inner shape of the outer edge 11 of the lower plate mold 10, and its thickness is determined by the molding space of the lower plate mold 10 ( 13) It is preferable that t1 is smaller than depth d.

This is configured so that the volume of the injection molded product 111 placed inside the outer edge 11 of the lower plate mold 10 is smaller than the volume of the molding space 13 of the lower plate mold 10, so that the molding space 13 ) is formed between the molding surface of the molding space 13 of the lower plate mold 10 and the molding surface of the protruding end 23 of the first upper plate mold 20 during the pressurization and heating process described later. This is to foam mold into the shape of excess space.

In the case where the linear molded body is made of a molded sheet 116 as shown in FIG. 7, it is manufactured into a foam sheet shape through T-die extrusion using a molding material mixed with a foaming agent, and then at least the outer edge of the lower plate mold 10 is formed. (11) It is desirable to have an area that can seal the outer part. At this time, the molded sheet 116, like the injection molded product 110 described above, is preferably made of a thickness t1 smaller than the depth d of the molding space 13 of the lower plate mold 10.

When a linear molded body such as the injection molded product 111 is manufactured, the linear molded body is placed in the lower plate mold 10 so that one side of the linear molded body faces the molding space 13 of the lower plate mold 10, as shown in FIG. 3, The first upper plate mold 20 is joined to the lower plate mold 10 so that one side of the first upper plate mold 20 on which the protruding end 23 is formed faces the other side of the linear member 110.

At this time, the present invention does not exclude the case where the linear forming body placed in the molding space 13 of the lower plate mold 10 consists of two or more pieces, and in addition, a single linear forming body is placed in the forming space 13 of the lower plate mold 10. After placing it in (13), it is not excluded to add additional molding materials to necessary areas in the molding space (13). In this case, each linear form may be made of a different material or color.

When the first upper plate mold 20 is joined to the lower plate mold 10 with the line forming body in between, as shown in the enlarged view, there is a gap △1 between one side of the linear forming body and the molding space 13 of the lower plate mold 10. A surplus space is formed. At this time, the gap △1 has a value of d - h - t1, and the surplus space formed by this becomes the foaming space of the preformed body. The foaming space due to the spacing △1 may vary depending on the shape of the molding space 13 and the protruding end 23 and the thickness of the linear formed body.

The present invention does not exclude the case where the hot melt film 140 is used when joining the first upper plate mold 20 and the lower plate mold 10. That is, as shown in FIG. 8A, after placing the linear body inside the outer edge 11 of the lower plate mold 10, one side of the hot melt film 140 is placed against the other surface of the linear body, and then the first That is, joining the upper plate mold (20) to the lower plate mold (10).

In this case, when the linear formed body is foamed during the heating process, the hot melt film 140 is combined with the other surface of the linear formed body, and the bond with the fabric 160, which will be described later, will be more firmly formed by the hot melt film 140. You can. If the main material forming the preform is made of a hot melt material with a relatively low melting point, a separate hot melt film is not needed. Reference numeral 141 denotes a release paper provided on the other side of the hot melt film 140.

Additionally, the present invention does not exclude the case where the synthetic resin film 150 is used as an intermediary when joining the first upper plate mold 20 and the lower plate mold 10. In this case, the synthetic resin film 150 is placed opposite the other surface of the lower plate mold 10 before placing the linear formed body inside the outer edge 11 of the lower plate mold 10, as shown in FIG. 8b. It is desirable.

The synthetic resin film 150 may be made of one or a combination of thermosetting materials such as PU or thermoplastic materials such as TPU, and may function as a skin layer of the product. In other words, the synthetic resin film 150 protects the surface area of the molded product that has a three-dimensional shape and protrudes to the outside and improves durability, thereby preventing the molded product from being damaged by external force during long-term use. Of course, the synthetic resin film 150 can have a different color from the linear molded body. At this time, the synthetic resin film may be integrated with the sheet-shaped linear body by coating and bonding it in advance.

When the synthetic resin film 150 is mediated by the linear molding body, the present invention does not exclude the case where a printing layer is formed on one side or the other side of the synthetic resin film 150. The printed layer can have any shape or various colors. When the synthetic resin film 150 functions as a skin layer that protects the three-dimensional shape of the product, the aesthetics of the product can be further improved if a printing layer is formed on the synthetic resin film 150.

When the first upper plate mold 20 is joined with the linear body placed in the lower plate mold 10, heat is supplied to the joined lower plate mold 10 and the first upper plate mold 20 while being pressed. When heat is supplied to the combined and pressurized lower plate mold 10 and the first upper plate mold 20, the linear mold is expanded through primary foaming by the foaming agent mixed into the linear mold. The primary foaming of the preformed body proceeds until it is formed into the shape of the forming space 13 and the protruding end 23, filling the excess space due to the gap △1 in FIG. 3.

At this time, since the volume of the linear body itself is smaller than the volume of the space between the forming space 13 and the protruding end 23, the linear forming body expands due to the supplied heat and fills the space between the forming space 13 and the protruding end 23. The excess material overflows beyond the boundaries of the outer edge 11 of the lower mold 10 and the first outer edge 21 of the first upper mold 20 and is foam-molded. This foam molding is the same even when the linear molded body is made of a molded sheet 116 as shown in FIG. 7.

When the linear mold is first foamed, heat transfer to the lower plate mold 10 and the first upper plate mold 20 is blocked, and the lower plate mold 10 and the first upper plate mold 20 are first cooled in a pressurized state. . When the lower plate mold 10 and the first upper plate mold 20 are first cooled in a pressurized state without opening the first upper plate mold 20, the first foam molded body is in an overflow state in the molding space 13. ) and is cooled in a molded state in the shape of the protruding end 23.

When the primary cooling is completed, the pressure is released and the first upper plate mold 20 joined with the lower plate mold 10 is opened, the first foam molded body 120 as shown in FIG. 4 is obtained. As shown in the enlarged view, the primary foam molded body 120 has a thickness t2 (t2 = d - h), and one side portion 121 thereof is foamed and molded into the shape of the molding space 13 of the lower plate mold 10, and the The other side portion 123 is foamed and molded into the shape of the protruding end 23 of the first upper plate mold 20.

In the case of the present invention, the primary foam 120 proposes a configuration in which the linear mold is first foamed and then cooled and molded in that state, and the above-described configuration that simply melts the material above the melting point is proposed. It is different from Republic of Korea Patent No. 1401489 and Republic of Korea Patent No. 1263209, respectively.

In explaining the first foaming and cooling steps for the preformed body, the present invention assumes that heating and cooling of the combined lower plate mold and the first upper plate mold are performed without releasing the pressure on the combined mold. , Of course, it is not excluded that the cooling step is performed after releasing the pressure on the joined mold.

When the primary foam molded body 120 is obtained, as shown in Figure 5a, each of the overflowed and unnecessary parts of the primary foam molded body 120 is removed and placed in the lower plate mold 10, and the primary foam molded body ( After placing the fabric 160 with one side facing the other side of the fabric 120, the second upper plate mold 30 is placed with one side of the second upper plate mold 30 facing the other side of the fabric 160. It is joined to the lower plate mold (10).

The fabric 160 according to the present invention may be made of either a natural material or an artificial material. If the fabric 160 is made of an artificial material, there is no limit to its type as long as it is classified and used as a fabric in the related industry. At this time, when placing the fabric 160 on the other side of the primary foam 120, the present invention, unlike the drawing, is when the fabric 160 is placed only on a specific area rather than the entire surface of the primary foam 120. It is not ruled out either.

As shown in FIG. 4, since the other side portion 121 of the first foam molded body 120 is molded into the shape of the protruding end 23 of the first upper plate mold 20, one side portion is flat. When the upper plate mold 30 is joined with the lower plate mold 10, as shown in Figure 5b, a surplus space is formed between the other side of the fabric 160 and one side of the second upper plate mold 30 due to the gap △2. . The gap △2 is equal to the vertical height h of the protruding end 23 of the first upper plate mold 10.

When the second upper plate mold 30 is joined with the first foam molded body 120 placed in the lower plate mold 10, the joined lower plate mold 10 and the second upper plate mold 30 are pressed and heated. supplies. When heat is supplied to the combined and pressurized lower plate mold 10 and the second upper plate mold 30, the primary foam molded body 120 undergoes secondary foaming and expands due to the foaming agent contained in the primary foam molded body 120. do. The expansion proceeds until the primary foam molded body 120 is molded into the shape of the molding space 13 and one side of the second upper plate mold 30, filling the excess space due to the gap △2 in FIG. 5B.

Similar to the primary foaming of the linear molded body, since the volume of the first foamed molded body 120 is smaller than the volume of the space between the molding space 13 and one surface of the second upper plate mold 30, the primary foaming due to the supplied heat The expansion of the foam molded body 120 occurs in the direction of the surplus space due to Δ2 and impregnates one side of the fabric 160 to a certain depth. In addition, since the overflowed portion has been removed after the first foaming and cooling molding steps, no overflow phenomenon occurs beyond the boundary of the first outer edge 21 of the lower plate mold 10.

When the primary foam molded body 120 is secondaryly foamed, heat transfer to the lower plate mold 10 and the second upper plate mold 30 is blocked, and the lower plate mold 10 and the second upper plate mold 30 are pressurized. Secondary cooling molding is performed. When the lower plate mold 10 and the second upper plate mold 30 are secondary cooled in a pressurized state without opening the second upper plate mold 20, one side of the secondary foam molded body is in the molding space 13. It is cooled as it is remolded into its shape, and the other side is integrated with the fabric 160 and cooled as it is molded into the shape of one side of the second upper plate mold 30. It is obvious that, like the first foaming and cooling steps, the second foaming and cooling steps can also be performed separately.

When the secondary cooling is completed, the pressure is released and the second upper plate mold 30 joined with the lower plate mold 10 is opened, a secondary foam molded body 130 as shown in FIG. 6 is obtained. As shown in the enlarged view, the secondary foam molded body 130 is foamed and molded in the shape of the molding space 13 of the lower plate mold 10 on one side 131, and the other side 133 is integrated with the fabric 160. It is foamed and molded in a 1:1 dimension corresponding to the shape and volume of the molding space inside the mold in the shape of the other side of the second upper plate mold 30.

The secondary foam molded body 130 integrated with the fabric 160 has a shape that corresponds 1:1 with the product originally intended to be implemented. As the secondary foam molded body 130 integrated with the fabric 160 is created, the present invention It's done. At this time, in the secondary foam molded body 130, the portion 132 is a portion that has been remolded by secondary foaming in the direction of the surplus space due to △2, and the portion 134 has been remolded with almost no secondary foaming, The density of area 132 is relatively lower than that of area 134.

As a result, the product itself is lightweight, and the outer edge of the product is closely coupled to the fabric 160, so it can have high durability even when external force is applied, and the part that protrudes in a three-dimensional shape has a cushioning feel. As a result, even if an external force acts, it is possible to quickly absorb and disperse it. In addition, even if the same material is used to foam, it is possible to manufacture a three-dimensional foam with differentiated density and physical properties for each part. When the product shown in Figure 6 is manufactured, in some cases, an additional process of removing unnecessary fabric parts through separate cutting, etc. may be carried out.

As described above, in the present invention, the secondary foam 130 integrated with the fabric 160 has dimensions that correspond 1:1 with the product to be implemented initially, which is the molding space of the lower plate mold 10 ( 13) This is because the shape is designed in advance to correspond 1:1 in size to the final product. Therefore, in the present invention, the secondary foam 130 is different from the above-mentioned Korean Patent No. 1263209, which proposes a configuration in which the secondary foam 130 is foam-molded to a size greater than a certain ratio than the molding space of the mold by rapidly opening the mold.

The present invention is different from the above-described embodiment in which the upper plate mold is separately composed of a first upper plate mold 20 having a protruding end 23 formed on one side and a second upper plate mold 30 whose one side is flat. It is not excluded that the mold 20, like the second upper plate mold 30, has one surface with a flat surface and goes through the first foam molding and second foam molding steps.

When one surface of the first upper plate mold 20 is made of a flat surface, the first upper plate mold 20 is joined with the linear member placed in the lower plate mold 10, and the joined lower plate mold 10 and the first plate mold 10 are formed. When heat is supplied while the first plate mold 20 is pressurized, the linear formed body has excess space due to the gap △1′ (= d - t1) rather than the gap △1 (= d - h - t1) in FIG. 3. The process proceeds until the forming space 13 of the lower plate mold 10 and the flat surface of the first upper plate mold 20 are formed while filling.

At this time, the surplus material of the linear mold overflows beyond the boundary of the outer edge 11 of the lower mold 10 and is foam molded. When the linear mold is first foamed, the lower mold 10 and the first upper mold 20 are formed. Heat transfer to is blocked, and the lower plate mold 10 and the first upper plate mold 20 are first cooled in a pressurized state. The lower plate mold 10 and the first upper plate mold 20 are first cooled in a pressurized state without opening the first upper plate mold 20, and as a result, the first foam molded body is placed in an overflowed state and the lower plate mold is cooled. It is cooled in a molded state in the flat surface shape of the molding space 13 of (10) and the first upper plate mold 20.

With the material overflowed, the linear body is molded into the flat surface shape of the molding space 13 of the lower plate mold 10 and the first upper plate mold 20, and the primary foam 120 is obtained, as shown in Figure 5a. After gently removing the overflowed area from the first foam molded body 120, it is placed in the lower plate mold 10, and one side of the fabric 160 is placed on the other side so that it faces each other, and then the second upper plate mold 30 is placed on the lower plate. Combined into mold (10).

At this time, a separate TPU film may be further interposed between the other side of the primary foam 120 and one side of the fabric 160. Additionally, the fabric 160 placed on the other side of the primary foam 120 may be made of any fabric having a mesh network structure.

Since one surface of the first upper plate mold 20 is made of the same flat surface as the one surface of the second upper plate mold 20, when the second upper plate mold 30 is joined with the lower plate mold 10, Figure 5b Unlike, one side of the fabric 160 and one side of the second upper plate mold 30 are in close contact with each other without any excess space due to Δ2. When the second upper plate mold 30 is joined with the first foam molded body 120 placed in the lower plate mold 10, the joined lower plate mold 10 and the second upper plate mold 30 are pressed and heated. supplies.

When heat is supplied to the combined and pressurized lower plate mold 10 and the second upper plate mold 30, the primary foam molded body 120 undergoes secondary foaming and expands due to the foaming agent contained in the primary foam molded body 120. do. Since one side of the primary foam molded body 120 has already been molded into the shape of the molding space 13 of the lower plate mold 10, when heat is supplied, the other side of the primary foam 120 expands and the fabric 160 ) is combined with.

This expansion continues until it is molded into the shape of the other surface of the second upper plate mold 30. If the fabric 160 has a mesh network structure, the other side of the primary foam 120 expands in a direction to be deeply impregnated into the fabric 160 and is tightly coupled to the fabric 160 as one piece.

At this time, the overflowed portion has already been removed, and the overflow phenomenon beyond the boundary of the first outer edge 21 of the lower plate mold 10 does not occur during secondary foaming. When the primary foam molded body 120 is secondaryly foamed, heat transfer to the lower plate mold 10 and the second upper plate mold 30 is blocked, and the lower plate mold 10 and the second upper plate mold 30 are pressurized. Secondary cooling molding is performed.

When the lower plate mold 10 and the second upper plate mold 30 are secondary cooled in a pressurized state without opening the second upper plate mold 20, one side of the secondary foam molded body is in the molding space 13. It is cooled as it is remolded into shape, and the other surface is tightly integrated and combined with the fabric 160, and at the same time, it is molded into the shape of the other surface of the second upper plate mold 30 and cooled.

When the secondary cooling is completed, the pressure is released and the second upper plate mold 30 joined with the lower plate mold 10 is opened, the secondary foam molded body 130 has a configuration similar to that shown in FIG. 6. is obtained. That is, one side portion 131 of the secondary foam 130 is foamed and molded into the shape of the molding space 13 of the lower plate mold 10, and the other side portion 133 is integrated with the fabric 160 and is formed into the second upper plate. It is foamed and molded inside the mold in the shape of the other surface of the mold 30.

9A to 9C each show photographs of a lower plate mold 10, a first upper plate mold 20, and a second upper plate mold 30 for manufacturing a shoe upper as an example according to the present invention. The largest d value among the molding spaces 13 in the lower plate mold 10 is 4 mm, and the largest h value among the protruding ends 23 in the first upper plate mold 20 is 2 mm.

Figure 10a is a photograph showing an example of a linear molding body made of the molding sheet 116. A molding material (foamed TPU) in which TPU is mixed with a pigment and a foaming agent is manufactured into a molding sheet with a thickness t1 of 1.5 mm, and then the lower plate is formed. It was cut to correspond to the shape of the outer edge of the molding space (13) of the mold (10) and to have an area that could seal the outer edge. Figure 10b shows an example of a photograph of a synthetic resin film 150 in which a printing layer 151 is formed on one side of a PU film with a thickness of 0.5 mm.

10C and 10D each show the upper portion of the lower plate mold 10 in a state in which the synthetic resin film 150, the linear molding body, and the hot melt film 140 are sequentially placed in the molding space 13 of the lower plate mold 10. After combining and pressurizing the first upper plate mold 20, heat is supplied in a pressurized state to produce the first foam molded body 120 through primary foaming and primary cooling molding, and then the first foam molded body 120 ) This is a photo of one side (the part exposed to the outside) and the other side after removing the overflowed part.

As can be seen in each photo, one side of the first foam molded body 120 is foamed and molded into the shape of the molding space 13 of the lower plate mold 10, and the other side is formed by the protruding end of the first upper plate mold 20. (23) It is formed by foaming into a shape. In other words, it is foamed and molded into the shape of the internal space of the joined lower plate mold 10 and the first upper plate mold 20. FIG. 10E is a photograph in which the release paper 141 in FIG. 10D has been removed.

10F and 10G each show that, after sequentially placing the first foam molded body 120 and the fabric 160 in the molding space 13 of the lower plate mold 10, a second upper plate is placed on the upper part of the lower plate mold 10. After the mold 30 is combined and pressurized, heat is supplied to perform secondary foaming, and one side of the secondary foam molded body 130 (exposed to the outside) is demolded through secondary cooling with the heat supply blocked. This is a photo of the affected area) and the other side (fabric area).

As shown in the photo, in the case of the secondary foam molded body 130, one side exposed to the outside is secondary foamed and remolded in the shape of the molding space 13 of the lower plate mold 10, and the other side is shown in Figure 5b. As it is secondaryly foamed into the surplus space formed by the gap △2, it is integrated with one side of the fabric 160 and is re-molded into the shape of one side of the second upper plate mold 30.

The table below shows the specific gravity values for each part of the secondary foam molded body 130 shown in FIG. 10f. As can be seen in the table, the specific gravity value of the relatively high protruding part (reference numeral 132) was 0.3, and the specific gravity value of the relatively low protruding part (reference numeral 134) was 0.6. Accordingly, the respective hardness values are 25 and 53, and the relatively low protruding portion 134 has higher density and tensile and tear strength than the portion 132.

Once the secondary foam 130 integrated with the fabric 160 is created, the shoe upper according to the present invention is completed by appropriately removing unnecessary fabric parts based on the originally intended design shape.

Figure 11 shows a photograph of a shoe upper manufactured through another example according to the present invention. The lower plate mold 10 of this shoe upper was manufactured using the same mold as shown in Figure 9a, and the first upper plate mold 20 was manufactured using a mold shown in Figure 9c rather than the mold shown in Figure 9b. That is, this is an example in which the first and second plate molds 20 and 30 are made of the same mold. The molding material used was a molding sheet 116 having the same thickness as that shown in FIG. 10A with different pigments, and the fabric 160 used was a fabric having a mesh network structure.

As shown in the photo, in the case of the secondary foam molded body 130, one side exposed to the outside is secondary foamed and re-molded in the shape of the molding space 13 of the lower plate mold 10 (see reference numeral 132 in the enlarged view). , As shown in the enlarged view, the other side of the first foam molded body 120 is deeply impregnated and integrated into the fabric 160 forming a mesh network structure, confirming that it has been remolded into the shape of one side of the second upper plate mold 30. You can.

Although the description above is limited to preferred embodiments of the present invention, this is only an example, and the present invention is not limited thereto and can be modified and implemented in various ways, and further, separate technical features are provided based on the disclosed technical idea. It is obvious that it can be added and implemented.

10: lower plate mold 20: first upper plate mold
30: Second upper plate mold 111: Injection molded product
116: Molded sheet 120: Primary foam molded body
130: Secondary foam molding 140: Hot melt film
150: synthetic resin film 160: fabric

Claims (9)

Preparing a thermoplastic synthetic resin molding material mixed with a foaming agent and excluding a crosslinking agent;
It has an outer border (11) on the other side having the same shape and area as the outer edge of the product, and a molding space (13) made of the same shape as the three-dimensional shape protruding to the outside of the product is provided inside the outer border (11). The lower plate mold (10) has a first outer border (21) on one side, which has the same shape and area as the outer border (11) of the lower plate mold (10), and has a lower plate mold (10) inside the first outer border (21). ), a first top plate mold 20 provided with a protruding end 23 that corresponds to the shape of the molding space 13 and has a volume smaller than the volume of the molding space 13, and a second top plate with one side having a flat surface. Preparing each mold 30;
Manufacturing a linear formed body using the prepared molding material so that the area located inside the outer edge 11 of the lower plate mold 10 has a volume smaller than the volume of the molding space 13 of the lower plate mold 10;
One side of the linear body is placed on the other side of the lower plate mold 10 in which the molding space 13 is formed, and then the first upper plate mold 20 is molded in a state where one side faces the other side of the linear body 110. A step of pressing the upper plate mold (20) by joining it with the lower plate mold (10);
Heat is supplied to the combined and pressurized lower plate mold 10 and the first upper plate mold 20, and the linear formed body is formed into the molding space 13 of the lower plate mold 10 and the protruding end 23 of the first upper plate mold 20. ) Primary foaming step of the preformed body, which is expanded and molded into each three-dimensional shape;
Blocking heat transfer to the lower plate mold (10) and the first upper plate mold (20), and then forming the joined and pressurized lower plate mold (10) and first upper plate mold (20) by primary cooling;
Releasing the pressure and opening the first upper plate mold (20) that was joined with the lower plate mold (10);
removing the overflowed portion beyond the outer edge 11 of the lower plate mold 10 and the first outer edge 21 of the first upper plate mold 20 in the foamed primary foam molded body 120;
In a state where the primary foam molded body 120 with the overflow area removed is placed in the lower plate mold 10, it has the same shape and area as the first outer border 21 of the first upper plate mold 20 and is formed on the first upper plate mold 20. One side of the fabric 160 is placed against the other side of the primary foam molded body 120, which is foamed and molded in the shape of the protruding end 23 of the mold 20, and then one side of the second upper plate mold 30 is placed against the other side of the first foam molded body 120. A step of pressing the second upper plate mold (30) into the lower plate mold (10) while facing the other side of the provisional fabric (160);
Heat is supplied to the joined and pressed lower plate mold 10 and the second upper plate mold 30, so that the lower plate mold 10 has an outer border of the same shape and area as the outer border 11, but one surface thereof is It is molded again into the shape of the molding space 13 of the lower plate mold 10, and the other surface of the primary foam molded body 120 molded into the shape of the protruding end 23 of the first upper plate mold 20 is expanded and the fabric ( 160) and a secondary foaming step of integration;
Blocking heat transfer to the lower plate mold (10) and the second upper plate mold (30), and then secondary cooling the joined and pressurized lower plate mold (10) and the second upper plate mold (30) to form them;
By releasing the pressure and opening the second upper plate mold (30) that was joined with the lower plate mold (10), the other side is expanded and molded into the shape of the other side of the second upper plate mold (30) and integrated with the fabric (160). Recovering the secondary foam molded body 130, one surface of which is molded into the shape of the molding space 13 of the lower plate mold 10;
A method of manufacturing a product in which a three-dimensional foam molding and fabric are integrated. According to paragraph 1,
The protruding end 23 of the first upper plate mold 20 is formed in the molding space 13 of the lower plate mold 10 at a point where the primary foam molded body 120 has different densities and requires foaming. A method of manufacturing a product in which the three-dimensional foam molding and the fabric are integrated. According to paragraph 1,
The lower plate mold 10 is composed of an auxiliary lower plate mold combined with the first upper plate mold 20 and a main lower plate mold combined with the second upper plate mold 30, and the main molding space formed in the main lower plate mold is the lower plate mold. It has the same shape and shape as the molding space 13 of the mold 10, and the auxiliary molding space formed in the auxiliary lower plate mold has the same shape and shape as the molding space 13 formed in the main lower plate mold. A method of manufacturing a product in which a three-dimensional foam molding and a fabric are integrated, characterized in that the volume is smaller than the volume of the main molding space. According to paragraph 1,
The linear formed body has a shape corresponding to the outer edge 11 of the lower plate mold 10, and the portion located inside the outer border 11 of the lower plate mold 10 is located in the molding space 13 of the lower plate mold 10. ), or is made of an injection molded product 111 with a volume smaller than the volume of ), or has an area that can be sealed to the outer edge of the outer edge 11 in the lower plate mold 10, but is limited to the molding space of the lower plate mold 10. A method of manufacturing a product in which a three-dimensional foam molding and a fabric are integrated, characterized in that it is made of a molded sheet (116) whose thickness is adjusted to have a volume smaller than the volume of (13). According to paragraph 1,
The combined mold of the first upper plate mold 20 and the lower plate mold 10 is a hot melt film in which the linear formed body is placed inside the outer edge 11 of the lower plate mold 10 and then a release paper 141 is provided on the other side. Characterized in that one side of the (140) is placed so as to face the other side of the linear formed body, and one side of the first upper plate mold (20) is molded into the lower plate mold (10) while facing the release paper (141). A method of manufacturing a product in which the three-dimensional foam molding and the fabric are integrated. According to paragraph 1,
Before placing the linear molded body inside the outer edge 11 of the lower plate mold 10, prepare a synthetic resin film 150 and place it so that one side faces one side of the lower plate mold 10, and the line A method of manufacturing a product in which a three-dimensional foam molding and a fabric are integrated, characterized in that the molded body is placed on the other side of the synthetic resin film (140). According to clause 6,
A method of manufacturing a product in which a three-dimensional foam molding and a fabric are integrated, characterized in that a printed layer having an arbitrary shape or color is formed on the other side of the synthetic resin film (150). According to paragraph 1,
One surface of the first upper plate mold 20 has the same flat surface as that of the second upper plate mold 30; In the first foaming step of the linear formed body, heat is supplied to the lower plate mold 10 and the first upper plate mold 20 that have been pressed together to form the linear formed body into the molding space 13 of the lower plate mold 10 and the first upper plate mold 10. It consists of a process of expanding and forming into a shape between the flat surfaces of the upper plate mold (20); A method of manufacturing a product in which a three-dimensional foam molding and a fabric are integrated. According to clause 8,
In the step of joining the second upper plate mold 30 to the lower plate mold 10, the fabric 160 placed on the other side of the first foam molded body 120 is a three-dimensional material, characterized in that it is made of a fabric having a mesh network structure. A method of manufacturing a product in which foam molding and fabric are integrated.

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