A moulding system for direct injection manufacturing of footwear

Patent metadata

Field	Value
Publication number	US-2022152963-A1
Application number	US-202017438778-A
Country	US
Kind code	A1
Filing date	Mar 12, 2020
Priority date	Mar 13, 2019
Publication date	May 19, 2022
Grant date	—

Abstract

A molding system for direct injection manufacturing of footwear. The molding system includes a mold cavity for receiving injection material for molding a sole part of the footwear. The system further includes a plurality of basic direct injection molds, each of which is attachable to injection molding equipment, and a plurality of sets of direct injection mold inserts, each set of direct injection mold inserts being configured to define at least part of an inner surface of the mold cavity when inserted in one of the plurality of basic direct injection molds. At least two of the plurality of basic direct injection molds differ from each other in size, corresponding to different ranges of sole part sizes.

First claim

1 . A molding system for direct injection production of footwear, said molding system comprising a mold cavity for receiving injection material for molding a sole part of said footwear, said molding system comprising:
a plurality of basic direct injection molds, each of which is attachable to injection molding equipment; and a plurality of sets of direct injection mold inserts, each set of direct injection mold inserts being configured to define at least part of an inner surface of said mold cavity when inserted in one of said plurality of basic direct injection molds, wherein at least two of said plurality of basic direct injection molds differ from each other in size, corresponding to different ranges of sole part sizes.

2 . The molding system according to claim 1 , wherein said plurality of basic direct injection molds is within an interval of 2-40.

3 . The molding system according to claim 1 , wherein number of said plurality of sets of direct injection mold inserts is within an interval of 2-40.

4 . The molding system according to claim 1 , wherein a set of said plurality of sets of direct injection mold inserts comprises a plurality of mold insert parts.

5 . The molding system according to claim 1 , wherein said plurality of sets of direct injection mold inserts is provided together with said plurality of basic direct injection molds.

6 . The molding system according to claim 1 , wherein said plurality of sets of direct injection mold inserts are manufactured by an additive manufacturing process.

7 . (canceled)

8 . The molding system according to claim 1 , wherein said plurality of sets of direct injection comprises one or more sets to be used in connection with each of the plurality of basic direct injection molds, and
wherein two or more sets of direct injection mold inserts that are useable in connection with one and the same basic direct injection mold differ from each other at least as regards the sole part size defined by said at least part of an inner surface of said mold cavity.

9 . The molding system according to claim 1 , wherein each of said plurality of basic direct injection molds is configured for at least partly channelling injection material to said mold cavity.

10 . The molding system according to claim 1 , wherein said basic direct injection molds are at least partly manufactured from metal.

11 . (canceled)

12 . The molding system according to claim 1 , wherein said sets of direct injection mold inserts are at least partly manufactured using an additive manufacturing material comprising one or more polymers, comprising one or more photopolymers, and/or comprising at least one material selected from a list of: polymers, resin photopolymers, ABS, PLA, ASA, nylon/nylon powder, PETG, metal/metal powder, plaster powder, HIPS, PET, PEEK, PVA, ULTEM, polyjet resin and/or ceramics.

13 . The molding system according to claim 1 , wherein each basic direct injection mold comprises a mold set of a first basic side mold, a second basic side mold, and a basic bottom mold.

14 . The molding system according to claim 1 , wherein heat conductivity of the plurality of basic direct injection molds at room temperature is above 50 W/(m*K).

15 . The molding system according to claim 1 , wherein heat conductivity of the plurality of direct injection mold inserts at room temperature is below 5 W/(m*K).

16 .- 20 . (canceled)

21 . A direct injection production method of footwear, said method comprising steps of, for a specified footwear design:
defining at least two different pre-defined footwear sizes to be produced; providing at least two basic direct injection molds, each of which is attachable to and operable with injection molding equipment; and for each of the at least two basic direct injection molds, providing at least one set of corresponding direct injection mold inserts, wherein the at least one set of corresponding direct injection mold inserts for each of the at least two basic direct injection molds define the at least two different pre-defined footwear sizes.

22 .- 29 . (canceled)

30 . The direct injection production method according to claim 21 , wherein a thermal conductivity of the at least two basic direct injection molds and the corresponding basic direct injection molds are different.

31 . The direct injection production method according to claim 21 , wherein the at least two basic direct injection molds are each attachable to injection molding equipment by means of a releasable fixing arrangement.

32 . The direct injection production method according to claim 21 , wherein the at least one set of direct injection mold inserts for each of the plurality of basic direct injection molds are defining different respective sizes of the pre-defined footwear sizes.

33 . (canceled)

34 . The direct injection production method according to claim 21 , wherein the plurality of basic direct injection molds are selected from a plurality of available basics molds.

35 . The direct injection production method according to claim 21 performed using a mold system comprising:
a plurality of basic direct injection molds, each of which is attachable to injection molding equipment; and
a plurality of sets of direct injection mold inserts, each set of direct injection mold inserts being configured to define at least part of an inner surface of said mold cavity when inserted in one of said plurality of basic direct injection molds,
wherein at least two of said plurality of basic direct injection molds differ from each other in size, corresponding to different ranges of sole part sizes.

36 . The direct injection mold system according to claim 21 , wherein mold insert material has a conductivity of less than 2 W/(m*K).

37 . The direct injection mold system according to claim 21 , wherein a maximum length of a direct heat transmission path HTPI should be below 12 cm.

38 . (canceled)

Assignees

• Ecco Sko As

Inventors

• Hansen Jakob Moller
• Mortensen Jens Sonne

Classifications

• B29D35/081

  by injection moulding · CPC title

• B29C45/17

  Component parts, details or accessories; Auxiliary operations · CPC title

• B29C45/14

  incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles {(B29C45/1671 takes precedence)} · CPC title

• B29D35/0045

  Sealing means for the mould cavity · CPC title

• B29D35/122

  Soles · CPC title