Patent Application
20220234256
This application claims priority to German Applications 10 2021 200 759.7, filed on Jan. 28, 2021 and 10 2021 205 928.7, filed on Jun. 11, 2021, the entire contents and disclosures of which are incorporated herein.
The present invention relates to a mold for molding a component, in particular a piece of sports apparel, a method for manufacturing the component using such a mold and a shoe with such a component.
The use of particle foam materials, i.e. materials made from individual particles of expanded plastic materials, has found its way into the manufacture of cushioning elements for sports apparel, particularly the manufacture of shoe soles for sports shoes. In particular, the use of particles of expanded thermoplastic polyurethane, eTPU, which are fused at their surfaces by subjecting them to pressurized steam within a mold (often called “steam chest molding” in the art), has been considered for the manufacture of shoe soles.
However, conventional molds for steam chest molding shoe soles are not adapted to the specific requirements of the used materials. For example, the steam chest molding process of a shoe sole made from particles with a conventional mold requires a large amount of energy for heating the mold, as conventional molds typically have a high mass. Moreover, the cooling process of such molds is slow and therefore leads to extended cycle times. Finally, steam chest molding shoe soles from particles requires to uniformly supplying the pressurized steam to the particles in order to achieve a homogeneous interconnection of the particles. Therefore, conventional molds are not adapted to such a uniform medium supply.
Energy carriers other than pressurized steam have also been considered. In particular, a method for the manufacture of a cushioning element for sports apparel that comprises loading a mold with a first material comprising particles of an expanded material and fusing the surfaces of the particles by supplying energy in the form of at least one electromagnetic field has been described in DE 10 2015 202 013 A1 and EP 3 053 732 A1. However, these methods leave still room for improvement, because they do not yet take full account of the specific material characteristics of the mold material that, in particular, for the manufacture of modern performance footwear like running shoes are necessary, specifically when it comes to their soles and midsoles.
It is an object underlying the present invention to overcome said disadvantages of the prior art and to provide an improved mold for molding a component, in particular a piece of sports apparel.
The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim.
In some aspects, the present disclosure relates to a mold for molding a component, the mold comprising: a. a mixture of a polymer material and a filler material, b. wherein the filler material is adapted to allow a heating of the component inside the mold by means of an electromagnetic field. In some aspects, the filler material may be adapted to increase the thermal conductivity of the mold. In some aspects, the filler material may be adapted to increase the permittivity of the mold compared to the component. The filler material may comprise a dielectric material comprising at least one of the following: a metal nitride, a metal oxide, a metal carbide, a metal sulfide, a metal silicate, a silicon carbide, silicon nitride, and combinations thereof. The filler material may comprise at least one of the following: a mixture of a carbon material and an inorganic material, carbon fiber, glassy carbon, carbon nanotubes, carbon nanobuds, aerographite, linear acetylenic carbon, q-carbon, graphene, a salt, a monocrystalline powder, a polycrystalline powder, an amorphous powder, a glass fiber, and combinations thereof. The mixture may comprise the filler material in an amount of 1 to 75% by volume. The polymer material may comprise a thermoplastic material comprising at least one of the following: polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyoxymethylene (POM), polyamide-imide (PAI), polycarbonate (PC), polyketones (PK), polyether ether ketone (PEEK), polyethylene (PE), and combinations thereof. In some aspects, the polymer material may be adapted to increase the permittivity of the mold compared to the component. In some aspects, the polymer material may be adapted to increase the dielectric loss factor of the mold. In some aspects, the polymer material may comprise a foamed material. The mold may be a sole mold and the component may be a shoe sole. The electromagnetic field may be in the radio frequency range of 30 kHz-300 GHz.
In some aspects, the present disclosure is directed to a method for manufacturing a component, the method comprising the step of a. molding the component using a mold comprising: a. a mixture of a polymer material and a filler material, b. wherein the filler material is adapted to allow a heating of the component inside the mold by means of an electromagnetic field. In some aspects, the filler material may be adapted to increase the thermal conductivity of the mold. In some aspects, the filler material may be adapted to increase the permittivity of the mold compared to the component. The filler material may comprise a dielectric material comprising at least one of the following: a metal nitride, a metal oxide, a metal carbide, a metal sulfide, a metal silicate, a silicon carbide, silicon nitride, and combinations thereof. The filler material may comprise at least one of the following: a mixture of a carbon material and an inorganic material, carbon fiber, glassy carbon, carbon nanotubes, carbon nanobuds, aerographite, linear acetylenic carbon, q-carbon, graphene, a salt, a monocrystalline powder, a polycrystalline powder, an amorphous powder, a glass fiber, and combinations thereof. The mixture may comprise the filler material in an amount of 1 to 75% by volume. The polymer material may comprise a thermoplastic material comprising at least one of the following: polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyoxymethylene (POM), polyamide-imide (PAI), polycarbonate (PC), polyketones (PK), polyether ether ketone (PEEK), polyethylene (PE), and combinations thereof. In some aspects, the polymer material may be adapted to increase the permittivity of the mold compared to the component. In some aspects, the polymer material may be adapted to increase the dielectric loss factor of the mold. In some aspects, the polymer material may comprise a foamed material. The mold may be a sole mold and the component may be a shoe sole. The electromagnetic field may be in the radio frequency range of 30 kHz-300 GHz. The method may further comprise at least one of the following steps of: b. loading the mold with a first material for the component which comprises particles of an expanded material; and c. heating the first material and/or the mixture of the polymer material and the filler material of the mold and/or a susceptor of the mold with the electromagnetic field. The susceptor may comprise at least one of the following materials: expanded polypropylene (ePP), polyurethane (PU), polylactide (PLA), polyether-block-amide (PEBA), polyethylene terephthalate (PET), and combinations thereof. The heating step may comprise the step of fusing the surfaces of the particles. The particles for the component may comprise at least one of the following materials: expanded thermoplastic polyurethane (eTPU), expanded polyamide (ePA), expanded polyetherblockamide (ePEBA), polylactide (PLA), polyether-block-amide (PEBA), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), thermoplastic polyester ether elastomer (TPEE), and combinations thereof. In some aspects, the particles may comprise a foamed material. The mold may be further loaded with a second material, which remains essentially unaltered by the electromagnetic field. The present disclosure also includes a component manufactured by the above method. The component may be a shoe sole. The present disclosure further includes a shoe comprising the component manufactured by the above method.
In the following detailed description, embodiments of the invention are described referring to the following figures:
This object is accomplished by the teachings of the independent claims. Beneficial embodiments are contained in the dependent claims.
In one embodiment, a mold for molding a component, in particular a piece of sports apparel, comprises (a.) a mixture of a polymer material and a filler material, (b.) wherein the filler material is adapted to allow a heating of the component inside the mold by means of an electromagnetic field.
The inventors of the present invention have surprisingly found that such a mold provides an improved approach for molding pieces of sports apparel. By using such a mixture of a polymer material and a filler material the specific characteristics of the mold material may be significantly improved without deteriorating the remaining material characteristics of the mold, e.g. its stability, during the molding process. Moreover, the use of an electromagnetic field, in particular electromagnetic radiation, for heating the piece of sports apparel inside the mold allows the manufacture of components with various thicknesses and complex geometry, too, since the energy for heating is not coupled to any kind of media transport, for example, the introduction of pressurized steam. The electromagnetic radiation may be chosen such that it permeates the mold loaded with the material for the piece of sports apparel essentially homogeneously and supplies an essentially constant amount of energy to all portions of the piece of sports apparel, such that a homogeneous and constant molding is achieved throughout the entire piece of sports apparel and in every depth of the piece of sports apparel.
It is explicitly mentioned at this point that, for clarity reasons, a filler material may be a solid additive incorporated into the polymer material. In this way, the filler material may be a functional filler used to improve the performance of the polymer mold material. In other words, when added to the polymer material, a particular property of the polymer mold material is improved, up to a certain extent, as the amount of filler material increases. Moreover, mixtures of fillers can help to “tailor” the material characteristics and balance mechanical performance with dielectric behaviour of the whole mold.
The filler material may be adapted to increase the thermal conductivity of the mold. As a consequence, the loss of heat energy when heating the mold as thermal inflow is significantly increased, because the heat flows away from the mold. Moreover, the increased thermal conductivity of the mold also improves the cooling process as thermal outflow after molding which is further supported by the mixture of a polymer material and a filler material according to the present invention. In addition, there is no further need for additional external or internal cooling of the component so that the whole molding process is simplified. Summarizing, the overall productivity of the manufacturing process for a piece of sports apparel may be increased by such a mold.
The term “thermal conductivity”, as used in the present application, refers to the ability of a mold material to conduct heat. In other words, the thermal conduction is defined as the transport of energy due to random molecular motion across a temperature gradient. It is distinguished from energy transport by convection and molecular work in that it does not involve macroscopic flows or work-performing internal stresses. In the International System of Units (SI), the thermal conductivity is measured in watts per meter and kelvin (W/(m·K)).
The filler material may be adapted to increase the permittivity of the mold compared to the component. Moreover, the filler material may comprise a dielectric material, e.g., a mixture of at least two inorganic materials. In some embodiments, the filler material comprises at least one of the following: a metal nitride, a metal oxide, a metal carbide, a metal sulfide, a metal silicate, a silicon carbide and silicon nitride. In some embodiments, the filler material comprises boron nitride, BN. The permittivity of the mold has a direct influence on the field strength of the electromagnetic field or electromagnetic radiation inside the mold (for a constant ‘external’ field being applied to the mold), as the skilled person understands, and will also influence the field distribution (e.g., the local value of the field strength) inside the mold. A further advantage of using an increased permittivity of the mold to influence the electromagnetic field distribution is that filler materials with a wide variety of permittivity-values are known and available, such that a large degree of tuning and adaption is possible in this manner, by choosing and/or combining different filler materials. Moreover, an increased permittivity of the mold may indirectly reduce the loss of heat energy during the molding process, in that the electromagnetic field density is concentrated on the component material—and away from the mold material itself.
Furthermore, the filler material may comprise at least one of the following: a mixture of a carbon material and an inorganic material, carbon fiber, glassy carbon, carbon nanotubes, carbon nanobuds, aerographite, linear acetylenic carbon, q-carbon, graphene, a salt, a monocrystalline powder, a polycrystalline powder, an amorphous powder, a glass fiber. Besides the effects mentioned above, fibers or fiber composite materials are lightweight yet exceptionally strong. In particular, glass or glass fibers are fairly cheap and are moisture resistant as well as have a high strength to weight ratio. Therefore, the mold materials may influence the performance of the whole process and a tailored selection of mold materials of different dielectric properties allows for achieving optimal properties for efficient dielectric heating and subsequent cooling. Moreover, a certain range of electrical resistivity and properties related to mechanical stability may also be considered in the selection of the materials.
All of these described embodiments with different filler materials having different shapes, optical, thermal and electrical properties or material characteristics follow the same idea of achieving optimal properties for efficient molding by dielectric heating of the piece of sports apparel inside the mold and the subsequent cooling of the whole mold. For example, if the piece of sports apparel to be molded is a shoe sole, both reduced cycle times when manufacturing the shoe sole and a high quality of the shoe sole may be provided with the mold of the present invention.
The term “sports apparel”, as used in the present application, may refer to clothing, including footwear and accessories, worn for sport or physical exercise. Sport-specific clothing or garments may be worn for most sports and physical exercise, for practical, comfort or safety reasons. Typical sport-specific garments may include tracksuits, shorts, T-shirts and polo shirts. Specialized garments may include swimsuits (for swimming), wet suits (for diving or surfing), ski suits (for skiing) and leotards (for gymnastics). Sports footwear may include trainers, football boots, riding boots, and ice skates. Sportswear also may include bikini and some crop tops and undergarments, such as the jockstrap and sports bra. Sportswear may be also at times worn as casual fashion clothing.
The mixture may comprise the filler material in an amount of 1 to 75% by volume, e.g., from 1 to 30% by volume, from 1 to 25% by volume, from 1 to 20% by volume, or from 5 to 20% by volume or the mixture may comprise the filler material in an amount of 10 to 40% by volume, e.g., from 15 to 35% by volume. The indicated values have been found to provide a reasonable compromise between optimized optical properties for efficient dielectric heating and sufficient thermal properties to provide increased thermal conductivity of the mold for the subsequent cooling.
The polymer material may comprise a thermoplastic material, e.g., at least one of the following: polyethylene terephthalate, PET, polybutylene terephthalate, PBT, polyoxymethylene, POM, polyamide-imide, PAI, polycarbonate, PC, polyketones, PK, polyether ether ketone, PEEK, or polyethylene, PE. Moreover, the polymer material may comprise a foamed material. These materials have turned out beneficial and may hence be used in the context of the present invention. For example, POM has a dielectric loss factor D of approximately 0.008 for radio frequency radiation. This material may thus be essentially transparent to radio frequency radiation, since it absorbs only a small part of the electromagnetic radiation and may, due to the relatively low loss factor, be formed with a certain thickness.
The polymer material may be adapted to increase the permittivity of the mold compared to the component. For example, certain polymer materials from certain polymer grades may be used due to their high intrinsic permittivity compared to the component material. Therefore, since the permittivity of the mold has a direct influence on the field strength of the electromagnetic field or electromagnetic radiation inside the mold, an optimized thermal inflow and outflow of the mold may be provided in that the electromagnetic field density is concentrated on the component material. Examples may comprise at least one of polyacrylonitrile, PAN, polyamide or polyethylene terephthalate, PET. In some embodiments, the mold may comprise a mixture of PET and 30% by volume of Aluminium oxide, Al2O3, or a mixture of POM and titanium dioxide (TiO2).
The polymer material may be adapted to increase the dielectric loss factor of the mold. It is also conceivable that certain portions of the mold may be adapted to increase the dielectric loss factor. Such embodiments allow to selectively introduce excessive heat buildup in the whole mold or only at specific portions within the mold by means of high dielectric loss since the mold material may absorb a high amount of the electromagnetic radiation. Therefore, an optimized thermal inflow and outflow of the mold may also be provided. Examples may comprise at least one of polyketones, PK, polyvinylidene fluoride or polyvinylidene difluoride, PVDF or polyamide-imide, PAI. In some embodiments, the mold may comprise a mixture of POM and titanium dioxide, TiO2.
The mold may be a sole mold and the component may be a shoe sole, in particular a midsole. The molding process by dielectric heating and the subsequent cooling process of the shoe sole are much faster so that the productivity may be improved. Moreover, the homogeneous and constant molding allows the manufacture of a lightweight, durable shoe sole that offers optimum cushioning properties.
The invention further concerns a method for manufacturing a component, in particular a piece of sports apparel, the method comprising the step of (a.) molding the component using a mold as described herein. Moreover, the method may further comprise at least one of the following steps: (b.) loading the mold with a first material for the component which comprises particles of an expanded material and (c.) heating the first material and/or the mixture of the polymer material and the filler material of the mold and/or a susceptor of the mold by means of an electromagnetic field. The susceptor may comprise at least one of the following materials: expanded polypropylene, ePP, polyurethane, PU, polylactide, PLA, polyether-block-amide, PEBA, or polyethylene terephthalate, PET.
The heating step may comprise the step of fusing the surfaces of the particles. As mentioned above, an electromagnetic field, in particular electromagnetic radiation, may be chosen such that it permeates the mold loaded with the particles essentially homogeneously and supplies an essentially constant amount of energy to all particles, such that a homogeneous and constant fusing of the particle surfaces is achieved throughout the entire component and in every depth of the component.
The particles for the component may comprise at least one of the following materials: expanded thermoplastic polyurethane, eTPU, expanded polyamide, ePA, expanded polyetherblockamide, ePEBA, polylactide, PLA, polyether-block-amide, PEBA, polyethylene terephthalate, PET, polybutylene terephthalate, PBT, thermoplastic polyester ether elastomer, TPEE. For example, for use in the manufacture of shoe soles, particles of eTPU, ePEBA and/or ePA have turned out beneficial and may hence be used in the context of the present invention.
The particles may be filled into the mold using conventional techniques known in the art, for example, pressure filling through a filling gate.
The particles may comprise a foamed material. For example, using a foamed material for both the particles and for the surface of the mold leads to a similar loss factor so that a substantially uniform heating of both the particles and the mold may be provided so that a better surface fusion of the component may be obtained.
The electromagnetic field may be in the radio frequency range of 30 kHz-300 GHz. The electromagnetic field may, for example, be supplied in the form of radiation in the microwave range, i.e. with a frequency in the range from 300 MHz-300 GHz.
Microwave generators are commercially available and may be implemented into a manufacturing device for using an inventive mold with comparatively little effort. In addition, it may be possible to focus the microwave radiation essentially onto a cavity of the mold in which the component material is loaded by a suitable device, such that the energy efficiency of a method using the mold is increased. Furthermore, the intensity and frequency of the microwave radiation may easily be changed and adapted to the respective requirements.
The electromagnetic field may be in the radio frequency range of 1 MHz-200 MHz, e.g., in the range of 1 MHz-50 MHz, or in the range of 25-30 MHz. In some embodiments, the electromagnetic field may have a frequency in the radio frequency range around 27.12 MHz. It is also conceivable that at least one radio frequency or radio frequency ranges may be used.
Radio frequency generators are also commercially available and may be easily implemented in a manufacturing device. Moreover, also radio frequency radiation may be focused on the respective parts of the manufacturing device and its intensity and frequency may be adapted to the requirements.
It is further possible that the electromagnetic field, in particular electromagnetic radiation, is supplied in a frequency range different from the frequency ranges mentioned above.
The mold may be further loaded with a second material, which remains essentially unaltered by the electromagnetic field. This may, for example, be a material the electromagnetic field permeates without being absorbed by the material to a noticeable degree. In particular, the second material may be free from electromagnetic field absorbing material. “Essentially unaltered” may mean that the second material does not melt or start melting or become softer or harder.
All described embodiments relate to improved methods of manufacturing a component, in particular a piece of sports apparel. Further details and technical effects and advantages are described in detail above with respect to the mold.
The invention also concerns a component, in particular a piece of sports apparel, manufactured with a method as described herein. Moreover, the component may be a shoe sole, in particular a midsole.
The invention also concerns a shoe, in particular a sports shoe, with a component as described herein.
The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.
Possible embodiments of the different aspects of the present invention are described in the following detailed description primarily with respect to molds for molding a piece of apparel, in particular a cushioning element such as a midsole. However, it is emphasized, that the present invention is not limited to these embodiments. Rather, it may also be used for different kinds of cushioning elements for sports equipment, for example, knee- or elbow protectors.
Reference is further made to the fact that in the following only individual embodiments of the invention may be described in more detail. However, the skilled person will understand that the optional features and possible modifications described with reference to these specific embodiments may also be further modified and/or combined with one another in a different manner or in different sub-combinations without departing from the scope of the present invention. Individual features may also be omitted if they are dispensable to obtain the desired result. In order to avoid redundancies, reference is therefore made to the explanations in the preceding sections, which also apply to the following detailed description.
The embodiment of
This comparison between the mold of the prior art and the invention on cooling performance improvement were created using a simulation model where both the dielectric heating phenomenon and the thermodynamic heat conduction were characterized by a fully coupled multiphysics simulation model. The model uses the finite element method for calculation of the thermal energy induced inside of the mold construction during the presence of a radio frequency electric field. Material models represent the dielectric properties of the shoe sole 120 and the parts of the sole mold 100 construction, and through standard dielectric heating equations the correlation of used materials to induced heating power may be calculated with partial differential equations.
The sole mold 100 according to the present invention comprises a mixture of a polymer material and a filler material, wherein the filler material is adapted to allow a heating of the midsole 120 inside the sole mold 100 by means of an electromagnetic field, in particular radio frequency radiation. As may be seen in
In the exemplary embodiment of
In the case shown in
In another embodiment of the invention being experimentally investigated, the sole mold comprises a mixture of foamed PET and BN as filler material in an amount of 15% by volume, which leads to a thermal conductivity of approx. 0.85 W/m·K. The inventors have found out that this experimentally investigated embodiment leads to a cooling time of approx. 5.9 min compared to 10 min for the conventional sole mold as mentioned above. In other words, the cooling time is approx. reduced by 41%.
The following
Values for the (relative) permittivity of materials with polyoxymethylene, POM, and polyethylene terephthalate, PET, over the temperature range from 20° C. to 100° C. (suitable for use in a sole mold 100), measured at a frequency of approx. 27.12 MHz, are shown in
Values for the dielectric loss factor of materials with POM and PET together with BN or SILATHERM® as filler materials according to the invention over the temperature range from 20° C. to 100° C. (suitable for use in a sole mold 100) are shown in
Values for investigating the storage modulus of materials with POM or PET and filler materials according to the invention over the temperature range from 20° C. to 160° C. are shown in
Values for investigating the thermal expansion of materials with POM or PET and filler materials according to the invention over the temperature range from 20° C. to 100° C. are shown in
Values for the thermal conductivity of POM and PET in combination with BN or SILATHERM® as filler materials with different filler concentrations are shown in
Next, the improvement of process cycle time by the use of modified mold materials is investigated. Here, unfilled POM and PET were used as mold material.
If POM is used as sold mold material (curve 710), the maximum temperature of the foam exceeds Tfuse by 18%. The mold's peak temperature was 43%. The process cycle is finished after 432 s. For PET as mold material (curve 720), the peak in foam temperature is 115%. The mold reaches a maximum temperature of only 39%. The demolding temperature (curve 730) in the foam is achieved after 413 s. The maximum temperatures reached in foam (curves 710 and 720) and mold (curves 740 and 750) are 4% higher for the use of POM. Due to POM's higher thermal conductivity, the foam temperature may be reduced faster in the beginning. As soon as the foam temperature reaches 75% of Tfuse cooling is equal for both mold materials. For lower temperatures, the cooling becomes faster for PET. This may be caused by the higher temperature difference between foam and mold for PET. It could be seen that the largest part of one cycle may be consumed by passive cooling. For the unfilled mold materials cooling takes 393 s (PET), respectively 412 s (POM). This may be caused by the low thermal conductivity of foam and mold material. The 20 s of heating are comparably short, independent of the mold material.
The same analysis was done for PET and 15% by volume of BN in
The skilled person will understand that other filler material(s) or mixtures as mentioned above are also conceivable. For example, the filler material may comprise a dielectric material, in particular a mixture of at least two inorganic materials, e.g., at least one of the following: a metal nitride, a metal oxide, a metal carbide, a metal sulfide, a metal silicate, a silicon carbide and silicon nitride. In some embodiments, the filler material comprises boron nitride, BN, SILATHERM® (a mixture of Al2O3 and SiO2) or SILATHERM® Advance. Alternatively or in addition, the filler material comprises at least one of the following: a mixture of a carbon material and an inorganic material, carbon fiber, glassy carbon, carbon nanotubes, carbon nanobuds, aerographite, linear acetylenic carbon, q-carbon, graphene, a salt, a monocrystalline powder, a polycrystalline powder, an amorphous powder, a glass fiber. As discussed above, all of these described embodiments follow the same idea of achieving optimal properties for efficient molding by dielectric heating of the midsole inside the sole mold and the subsequent cooling of the sole mold and the midsole.
Alternatively or in addition, it is also possible to choose a filler material to get defined physical or mechanical properties in different areas of the component, in particular a piece of sports apparel like the midsole 120 by the use of an inventive mold according to the present invention. This may include different degrees of fusion in these different areas and thus graded physical or mechanical properties in the midsole 120. For example, different mixtures of the polymer material and the filler material may be used in different areas of the mold. Therefore, such embodiments open up the possibility to provided graded and thus tailored midsole properties in a reproducible manufacturing process.
Summarizing, the use of an inventive sole mold can therefore not only provide better quality end products, it can also provide significant benefits for the whole molding process like reduced cycle times in the particular in the field of sports apparel, in particular for shoe soles, so that the overall productivity may be increased.
In the following, further examples are described to facilitate the understanding of the invention:
Example 1. A mold (100) for molding a component (120), in particular a piece of sports apparel (120), the mold (100) comprising: a. a mixture of a polymer material and a filler material, b. wherein the filler material is adapted to allow a heating of the component inside the mold (100) by means of an electromagnetic field.
Example 2. The mold (100) of Example 1, wherein the filler material is adapted to increase the thermal conductivity of the mold (100).
Example 3. The mold (100) of Example 1 or 2, wherein the filler material is adapted to increase the permittivity of the mold (100) compared to the component (120).
Example 4. The mold (100) of one of the preceding Examples, wherein the filler material comprises a dielectric material, in particular a mixture of at least two inorganic materials, preferably at least one of the following: a metal nitride, a metal oxide, a metal carbide, a metal sulfide, a metal silicate, a silicon carbide and silicon nitride, most preferably boron nitride, BN.
Example 5. The mold (100) of one of the preceding Examples, wherein the filler material comprises at least one of the following: a mixture of a carbon material and an inorganic material, carbon fiber, glassy carbon, carbon nanotubes, carbon nanobuds, aerographite, linear acetylenic carbon, q-carbon, graphene, a salt, a monocrystalline powder, a polycrystalline powder, an amorphous powder, a glass fiber.
Example 6. The mold (100) of one of preceding Examples, wherein the mixture comprises the filler material in an amount of 1 to 75% by volume, in particular 1 to 30% by volume, preferably 1 to 25% by volume, more preferably 1 to 20% by volume, most preferably 5 to 20% by volume or the mixture comprises the filler material in an amount of 10 to 40% by volume, in particular 15 to 35% by volume.
Example 7. The mold (100) of one of the preceding Examples, wherein the polymer material comprises a thermoplastic material, preferably at least one of the following: polyethylene terephthalate, PET, polybutylene terephthalate, PBT, polyoxymethylene, POM, polyamide-imide, PAI, polycarbonate, PC, polyketones, PK, polyether ether ketone, PEEK, or polyethylene, PE.
Example 8. The mold (100) of one of the preceding Examples, wherein the polymer material is adapted to increase the permittivity of the mold (100) compared to the component (120).
Example 9. The mold (100) of one of the preceding Examples, wherein the polymer material is adapted to increase the dielectric loss factor of the mold (100).
Example The mold (100) of one of the preceding claims, wherein the polymer material comprises a foamed material.
Example 11. The mold (100) of one of the preceding Examples, wherein the mold (100) is a sole mold (100) and the component (120) is a shoe sole (120), in particular a midsole (120).
Example 12. The mold (100) of one of the preceding Examples, wherein the electromagnetic field is in the radio frequency range of 30 kHz-300 GHz, preferably in the range of 1 MHz-200 MHz, more preferably in the range of 1 MHz-50 MHz, most preferably in the range of 25-30 MHz.
13. A method for manufacturing a component (120), in particular a piece of sports apparel (120), the method comprising the step of a. molding the component (120) using a mold (100) according to one of the preceding claims.
Example 14. The method of the preceding Example, further comprising at least one of the following steps of: b. loading the mold (100) with a first material for the component (120) which comprises particles of an expanded material; and c. heating the first material and/or the mixture of the polymer material and the filler material of the mold (100) and/or a susceptor of the mold (100) by means of the electromagnetic field.
Example 15. The method of the preceding Example, wherein the susceptor comprises at least one of the following materials: expanded polypropylene, ePP, polyurethane, PU, polylactide, PLA, polyether-block-amide, PEBA, or polyethylene terephthalate, PET.
Example 16. The method of Example 14 or 15, wherein the heating step comprises the step of fusing the surfaces of the particles.
Example 17. The method of one of Examples 14-16, wherein the particles for the component comprise at least one of the following materials: expanded thermoplastic polyurethane, eTPU, expanded polyamide, ePA, expanded polyetherblockamide, ePEBA, polylactide, PLA, polyether-block-amide, PEBA, polyethylene terephthalate, PET, polybutylene terephthalate, PBT, thermoplastic polyester ether elastomer, TPEE.
Example 18. The method of one of the Examples 14-17, wherein the particles comprise of a foamed material.
Example 19. The method of one of the Examples 13-18, wherein the electromagnetic field is in the radio frequency range of 30 kHz-300 GHz, preferably in the range of 1 MHz-200 MHz, more preferably in the range of 1 MHz-50 MHz, most preferably in the range of 25-30 MHz.
Example 20. The method of one of the Examples 14-19, wherein the mold (100) is further loaded with a second material, which remains essentially unaltered by the electromagnetic field.
Example 21. A component (120), in particular a piece of sports apparel (120), manufactured with a method according to one of the Examples 13-20.
Example 22. The component (120) of the preceding Example, wherein the component (120) is a shoe sole (120), in particular a midsole (120).
Example 23. A shoe, in particular a sports shoe, with a component (120) of Example 21 or 22.
Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2021 200 759.7 | Jan 2021 | DE | national |
| 10 2021 205 928.7 | Jun 2021 | DE | national |
