EP2929792B1 - Foam plastic shoe insole blank with covering and method for applying same - Google Patents

Description

The invention relates to foam plastic shoe insole blanks with a three-dimensionally formed footbed on its upper side, wherein the foam plastic shoe insole blanks are produced by a foaming process and provided after foaming with a blanket on its top and / or bottom. The invention further relates to a method of applying a blanket to such foam plastic shoe insole blank. Foamed plastic shoe insole blanks relating to the invention are foamed in a foaming mold having a shoe insole-like negative mold for this purpose. In particular, such foamed plastic shoe insole blanks are made of EVA or PU foam. In particular, the foamed plastic shoe insole blanks relating to the invention are produced by the RIM process.

Foamed plastic shoe insole blanks, which have been produced in a foaming process, after their removal from a foaming mold have an unfinished, crude or unattractive, not particularly appealing, usually one or two-tone appearance. Such a simple and simple appearance offers, as it understands itself, no special incentive to buy, let alone a sales-promoting look. At the same time, a bare foam plastic surface causes an uncomfortable wearing feeling.

To improve the appearance, foam plastic shoe insole blanks are provided on their top and / or bottom with a blanket / cover which gives the foam plastic shoe insole blank a more pleasing look. Applying a blanket also improves the wearing comfort of the shoe insole blank. For conventionally used blankets, which are also referred to as a cover of a foam plastic shoe insole blank, usually Alcantara, leather, imitation leather, textile, nonwoven, cork or similar mostly textile materials can be used. In the prior art, such ceilings are applied, for example by means of a hot melt adhesive to the foam plastic of the shoe insole blank, including the ceiling material However, it must first be coated with a film, so that the hot melt adhesive is not absorbed by the ceiling material or this is penetrated by the adhesive.

Out DE 20 2005 018 920 For example, shoe soles, in particular shoe outer soles, made of PU solid material or PU composites are known, which are melt-bonded during a melting process of the material used (hot casting process) with a thermal transfer layer to produce a decoration. The thermal transfer layer is for example made of thermoplastic polyurethane (TPU), which combines well with the PU melt. Here, the thermoformed before melting (molding) in the mold film forms the bottom of the later shoe insole. This in DE 20 2005 018 920 U1 described method is largely limited to TPU films, since only these form a good connection to the molten PU. In addition, a TPU film is a very limited in terms of variability of the decor embellishment of a shoe insole. In addition, a TPU film on the bottom can not improve the comfort of a shoe insole and must when used on a top of a shoe insole, with an additional Ceiling be provided so that a comfortable fit for the wearer of such shoe insole is achieved. With regard to the variability of the decoration, the above-mentioned method is very limited, since the TPU films used for the most part are usually monochrome and / or transparent.

DE 20 2006 003 317 U1 from which the preamble of the inventive method for applying a blanket emanates, shows a multi-layered shoe insole, in the production of two blankets, an upper ceiling and a lower ceiling, are crimped together, then glued together on a foot-side surface of a shoe insole blank to become. In this case, recesses are provided in the upper ceiling through which the lower ceiling is visible. In one embodiment, the buffed ceiling is foamed during formation of the PU foam plastic base body in a foaming mold.

The object of the invention is therefore to provide a method with the blankets for foam plastic shoe insole blanks of different materials and different decorations in a simple manner, inexpensive with simple means on a on the top of a three-dimensionally formed footbed having foam plastic shoes insole blank both can be applied on the top and on the underside, with a good connection between the ceiling and the foam plastic material should be guaranteed.

The object is achieved by a method for applying a blanket according to claim 1, wherein the dependent claims on claim 1 are directed to preferred embodiments.

In the method according to the invention for applying a blanket to a foamed plastic shoe insole blank produced by a foaming process with a three-dimensional footbed on the upper side, the blanket is provided with a TPU layer on its rear side before being applied to the foamed plastic blank. In a subsequent step, the thus-coated blanket on an upper side and / or lower Side of the foam plastic shoe insole blank directly, without applying other auxiliaries or adhesives, ironed on the foam plastic. This subsequent step can also take place, for example, by an orthopedic technician, for example after a milling or grinding of the top or bottom side of the foam plastic shoe insole blank in a shoe orthopedic workshop, to the foam plastic shoe insole blank to customize an individual foot shape. The process step of directly ironing a TPU-coated blanket on one of the foam plastic surfaces of the foam plastic shoe insole blank can of course also be made by the manufacturer of the foam plastic shoe insole blank and is thus encompassed by the spirit of the invention. For the sake of simplicity, the description of the invention will be described with reference to a TPU film, however, any other way of applying a TPU layer to a back of a shoe sole cover is included in the inventive concept, in which case, for example, spraying, brushing, rolling or a direct Coating can be thought of. In a preferred embodiment, the TPU layer used for the method according to the invention is made available as a film roll material and applied to a foam plastic shoe insole blank on the backside of the same before ironing a blanket.

Furthermore, in a further embodiment of the method according to the invention, the necessary for foaming the foam plastic shoe insole blank for molding release agent on the top and / or bottom to which the TPU-coated blanket is to be ironed, remain. If no release agent for removing the blank from the foaming mold prior to introducing the foamed plastic material into the foaming mold, the foamed plastic sticks to the foaming mold and the foamed plastic shoe insole blank can not be removed from the foaming mold in a non-destructive manner. The inventive method accordingly relates to foam plastic shoe insole blanks, which are produced in a foam, which has been coated with foaming agent before foaming, so that the molded foam plastic body can be removed from the mold. To obtain a foamed plastic shoe insole blank had to be removed in the previously used method, this release agent, so that a application of a blanket was possible. In the conventionally used adhesive methods, in particular using hot melt adhesives or self-adhesive foils, due to the release agent remaining on the foamed plastic body during foaming, no adhesive bond could be achieved between the cover and the foamed plastic body if the release agent had not been removed. With the method according to the invention, it is therefore possible foamed plastic shoe insole blanks produced in the foaming process without Removing the release agent to Obtain, wherein the foamed plastic shoe insole blank before covering, for example, on the top and / or bottom mechanically, such as by grinding or milling, can be processed to about the preformed on the top, three-dimensionally formed footbed to a customize individual foot shape or, for example, the curvature on the underside individually or possibly to a Schuhinnenform.

The use according to the invention of a cover coated on its back with TPU and the ironing method used according to the invention combines the foam plastic used in foaming the foam plastic shoe insole blank with the TPU layer, which in turn is connected to the cover. This compound also arises according to the invention when the release agent is applied to the surface covered with the blanket, i. is to be ironed remains. By fusing the TPU layer to the foamed plastic, a stable and durable bond is achieved between the ceiling and the foam plastic body.

In the method according to the invention, a thin TPU film is preferably used which softens or at least melts during the ironing process by the action of heat, so that a fusion bond is formed between the TPU film and the surface of the foam plastic body. The TPU films used in this case have a thickness of preferably 10 .mu.m to 100 .mu.m, which is more preferably between 20 and 50 microns. The thickness of the TPU film or the layer thickness of the TPU layer can be selected depending on the coating method used for the ceiling, or can be selected depending on the heat to be introduced during the application of the TPU film-coated blanket on the foam plastic body.

According to the invention, a blanket coated with a TPU can be directly ironed on without removal of the (excess) release agent which adheres to the foam plastic body after removal of the foam plastic body from the foaming mold, ie applied to the blank under the action of heat and pressure. In this context, "direct" in the sense of the invention means that the TPU layer directly comes into contact with the release agent, without further applied auxiliaries and adhesives, with the surface to be bonded. Direct within the meaning of the invention is not to be read in terms of time, since the ironing of the TPU coated ceiling can be done both by the manufacturer of foam plastic shoe insole blank, as well as in a specialized after the foam plastic shoe insole blank, for example, individually to a Foot shape was adjusted.

When ironing on the back with TPU coated blanket, the front of the blanket in one embodiment of the method according to the invention preferably by hot pressing, in particular with an ironing press with a plate, roller or roller press or with a punch, which more preferably has the shape of a last , subjected to pressure and heat. When using soft cushion foams as foamed plastic shoe insole blank material, which preferably exhibit high elastic recovery, the foamed plastic shoe insole blank can be pressed into a nearly planar shape during braiding. According to the invention, such three-dimensionally shaped foam plastic shoe insole blanks are preferably provided with a footbed formed on the upper side in a quasi-continuous Pressbügelverfahren with a blanket, which has as a primer on its back only a TPU film. If harder foamed plastics are used to produce the foamed plastic shoe insole blanks, which can not be flattened without damaging the foamed plastic shoe insole blank, in particular when the upper side is pulled on, an adapted press-on device may be provided for the ironing process in order to make the blanket flat on the foam plastic surface to press. In general, the thicker the TPU layer, the more heat must be applied to the front of the blanket via the ironing plate or temple, or a bow roller, to allow the TPU layer and / or the plastic foam to reach softening temperature. Needless to say, the effect of heat, both in terms of its height and in terms of its duration, may only be so great that the material of the ceiling is not damaged.

Moreover, by using a foaming process to produce a foamed plastic shoe insole blank and the use according to the invention of a TPU-coated blanket which is ironed onto the foamed plastic shoe insole blanks according to the invention, the removal of a release agent used in the foaming process is no longer necessary , By ironing the TPU layer or the TPU coated on the back cover, a material bond between the TPU layer and the foam plastic shoe insole blank is achieved. An adhesion prevention by the release agent can be circumvented so.

As indicated above, according to the invention melts the TPU layer on the back of the ceiling during the ironing process and connects to the possibly also fused foam plastic foam plastic shoe insole blank, whereby the two materials merge together, so to speak "welded" together. The method according to the invention is preferably used for foam plastic shoe insole blanks made of PU, which were produced more preferably in the RIM process, applied. The TPU used in this case has an approximately the same high melting point as the foamed plastic, resulting in a stable and durable connection of the two materials. In particular, in the material pairing PU foam and TPU can be dispensed with large layer thicknesses, whereby the heat input necessary for connecting or for applying a blanket can be reduced to a minimum.

With the method according to the invention several steps are saved, including the removal of release agent and / or the application of another adhesion-promoting layer or the application of an adhesive for fixing a ceiling on a top or bottom of a shoe insole blank. It is irrelevant for the execution of the method according to the invention, whether the ceiling by a Schuhorthopädietechniker or an orthopedist - after any necessary customization of the foam plastic shoe insole blank to the foot of the wearer of the shoe insole - is applied, or already after the foaming of the Foam plastic shoe insole blanks in blank manufacturing plant.

, With the method according to the invention, ceilings of almost all conventional ceiling materials can be applied to a foamed plastic shoe insole blank, in particular blankets made of alcantara, leather, textile, fleece, fur and / or other materials that improve the wearer comfort and / or decor, which may also be may be formed of plastic. In this case, according to the invention, the manner of heat input into the bonding layer is not crucial. The required pressure forces can in turn be applied by rollers, rollers, punches or strips, with a temporary deformation of the foam plastic shoe insole blank in the elastic range is allowed.

Although the method of the invention is preferably applied to foamed plastic shoe insole blanks made of PU foam, which are more preferably made by the RIM process, the inventive method can also be applied to foam plastic shoe insole blanks made of EVA Foam were foamed. Of course, the method according to the invention can also be used when the foamed plastic shoe insole blank is made of a plurality of optionally different foamed plastic materials, which in particular have different material hardnesses. Thus, for example, the method according to the invention can equally well be applied to foamed plastic shoe insole blanks whose forefoot region has been foamed, for example, from a softer foam plastic material and whose midfoot region or heel region has a harder material.

Usually, a harder foam plastic material is used to support the midfoot area than in the heel area, since this is designed to soften or damp the appearance possibly softer. Optionally, for this purpose, in the heel area and possibly also in the metatarsal area, a core part is integrated into the foam plastic shoe insole blank or foamed onto it and forms, for example, its underside in partial areas. For example, the core member has a three-dimensional foot-supporting function for guiding the heel in horizontal directions, for example. At the same time, the core part can be designed so that its midfoot region has a curvature that supports the arch of the foot. Such a core part will in this case have a greater material hardness than the foamed plastic foamed thereon. If such a core part is likewise made of foamed plastic, preferably also of PU or EVA foam plastic, then a TPU-coated blanket can also be ironed onto it in accordance with the invention.

Figur 1:

eine mit TPU beschichtete Decke zum Aufbringen auf einen Schaumkunststoff-Schuheinlegesohlen-Rohling in einer perspektivischen Querschnitts-Darstellung;

Figur 2:

einen Schaumkunststoff-Schuheinlegesohlen-Rohling, der mit einer beschichteten Decke gemäß Figur 1 auf seiner Oberseite versehen werden soll in einer perspektivischen Querschnitts-Darstellung;

Figur 3:

den in Figur 2 gezeigten Schaumkunststoff-Schuheinlegesohlen-Rohling mit erfindungsgemäß aufgebrachter mit TPU beschichteter Decke gemäß Figur 1 auf seiner Oberseite in einer perspektivischen Querschnitts-Darstellung.

The method according to the invention will be explained in more detail below with reference to figures, wherein the embodiments shown in the figures do not limit the scope of protection or the inventive concept and further embodiments obvious to the person skilled in the art, which are not shown in the figures, are included in the scope of the invention , Showing:

FIG. 1:

a TPU coated blanket for application to a foam plastic shoe insole blank in a perspective cross-sectional view;

FIG. 2:

a foam plastic shoe insole blank covered with a coated blanket according to FIG. 1 to be provided on its upper side in a perspective cross-sectional view;

FIG. 3:

the in FIG. 2 shown foamed plastic shoe insole blank according to the invention with TPU coated blanket according to FIG. 1 on its upper side in a perspective cross-sectional view.

FIG. 1 shows a ceiling 10 in a longitudinal section in a three-dimensional (perspective) view. The ceiling 10 has on its rear side 13 a connected to the ceiling 10 TPU layer 11. The TPU layer is shown in this embodiment as a TPU film 11 and is further attached, for example, with a pressure-sensitive adhesive or the like on the back 13 of the ceiling 10. In the illustration in FIG. 1 the proportions, in particular the thickness ratios for reasons of representability and for explanatory purposes disproportionate shown big. In a real embodiment, the TPU film 11 has a thickness of preferably between 10 .mu.m and 100 .mu.m, wherein the layer thickness of the blanket may be in the millimeter range. The ceiling 10 may, as described in the general part described above, be made of all materials that are suitable as a blanket for a shoe insole. In the FIG. 1 shown ceiling 10 has in the heel area 5 to identify a heel 8 an optically remote area. This optically offset region of a heel recess 8 can be provided in a different color or, for example, as a recess, for example for the passage of a gel pad. In the forefoot area 3 as well as in the metatarsal area 4, the in FIG. 1 shown ceiling 10 no additional orthopedic or comfort-enhancing accessories on what, of course, is included in the concept of the invention.

FIG. 2 shows a foamed plastic shoe insole blank 1 made of foam plastic, which shows on its upper side a three-dimensionally formed footbed. The foam plastic shoe insole blank 1 has in the heel area 5 a heel recess 8, which with the marking of the heel cup of in FIG. 1 shown ceiling 10 corresponds. Below the heel region 5 and also protruding into the midfoot region 4, the in FIG. 2 foam plastic shoe insole blank 1 shown on its underside 6 a core part 9, which has been foamed, for example, as an insert during foaming of the foam plastic shoe insole blank 1 in the foam in the foaming and so connected to the foam plastic. The foamed plastic 7 used for producing the foam-plastic shoe insole blank 1 is, for example, PU or EVA, wherein, for example, the RIM method is used when using PU foam.

FIG. 3 shows the in FIG. 2 Foam plastic shoe insole blank 1 shown after the in FIG. 1 shown ceiling 10 was ironed on its top 2. In the FIG. 3 shown proportions, in particular the thickness ratios of the TPU film 11 to the other layers do not correspond to the real dimensions and are shown greatly enlarged for purposes of illustration. The TPU layer / TPU film 11 disposed between the top 10 and the top 2 of the foamed plastic 7 of the foam plastic shoe insole blank 1 is, as well as in FIG FIG. 1 , shown exaggeratedly thick, so that these in the FIGS. 1 and 3 is recognizable. As already mentioned, in the method according to the invention, for example, TPU films 11 having layer thicknesses of 10 to 100 μm are used. Such a wall thickness, however, can not be represented graphically in the unimpeded thickness ratio. Therefore, the in FIG. 3 shown shoe insole thicker than it is in reality.

A foamed plastic shoe insole blank 1 obtained by the method according to the invention has at least three layers: a foamed plastic layer 7, a TPU layer / TPU foil 11 and a cover 10. The cover 10 is over the TPU foil 11 mounted on its rear side 13 connected by ironing with the foam plastic 7 with the top 2 and / or bottom 6 of the foam plastic body of the shoe insole blank 1.

Not only for the skilled person can be seen from the illustrated figures and the above statements that the shoe insole blank 1 can also be provided on its underside 6 with a ceiling 10, wherein between the ceiling 10 and the foam plastic 7 another layer of TPU film 10 would be arranged. Needless to say, both sides, that is to say the upper side 2, which has a three-dimensionally formed footbed, and the possibly arched underside 6 can be covered with a blanket according to the invention. Is, as in the FIGS. 2 and 3 shown, the blank taken from the Ausschäumform blank, for example, provided with a core part 9, it can also be ironed with a cover 10 according to the invention or related by ironing, if this example, also made of foamed plastic, ie foamed.

The inventive application of a blanket on a foamed plastic foam shoe insole blank 1 produced in a simple manner provides a visually appealing and high wearing comfort having robust and abrasion-resistant foam plastic shoe insole blank or shoe insole, its production due to the direct ironing a with TPU film 11 coated ceiling 10 is inexpensive. The foamed plastic shoe insole blank 1 produced and / or purchased in accordance with the invention is highly resistant to detachment of the blanket from the foamed plastic 7, since the blanket is preferably connected in a planar manner to the foamed plastic.

In particular, the fact that the necessary during foaming of the shoe insole blank release agent during application of the ceiling does not have to be removed, the inventive method offers a high cost savings. To save costs further contributes that the applied ceiling before its application, ie in a flat and flat state in a simple manner on its back, for example, with a TPU film, optionally in a continuous process can be coated. Thus, for both the blanket and the TPU for coating the blanket 10 on its backside, an endless roll material can be used. For example, a blanket 10 thus coated with TPU film 11 may be replaced by a blank prior to being applied to a foam plastic shoe insole blank 1 projected shoe contour are punched out. The cutting of the blankets, however, can take place in another embodiment only after the application of the blanket 10 according to the invention. If the blanket 10 is applied, for example, in a shoe orthopedics workshop, it may be appropriate to make a subsequent blank, wherein the blanket 10 coated with TPU film 11 is made available, for example, as roll material or as a blank. Suitably, the blanket 10 coated with TPU film 11, prior to ironing, has a protective film on the surface to be bonded, which is removed prior to ironing.

To obtain a foam plastic shoe insole blank 1 with a cover 10 according to the invention an additional application of auxiliaries or adhesives on the surface of the foam plastic body on which the ceiling is to be applied, or on the TPU film 11 is not necessary. The TPU film 11 according to the invention after the ironing process, the connection between the ceiling 10 and the foam plastic 7 ago. Preferably, this compound is a fusion compound, whereby it is accordingly robust and peeling of the cover 10 is prevented from the foam plastic body of the foam plastic shoe insole blank 1.

LIST OF REFERENCE NUMBERS

1

Foam plastic shoe insoles blank

2

top

3

forefoot

4

midfoot

5

heel

6

bottom

7

Plastic foam

8th

heel cup

9

core part

10

blanket

11

TPU layer

12

front

13

back

Claims (11)

1. Method for applying a covering (10) to a foam plastic shoe insole blank (1) which has been produced in a foaming process and which has, on an upper side (2), a footbed moulded three-dimensionally from foam plastic (7), where, before application, the covering (10) is provided on its reverse side (13) with a TPU layer (11), characterized in that the covering (10) is then ironed with its coated side onto the foam plastic (7) of the upper side (2), or of an underside (6), of the foam plastic shoe insole blank (1) without any other auxiliary materials or adhesives.
2. Method according to Claim 1, in which the thickness of the TPU layer (11) is from 10 µm to 100 µm.
3. Method according to Claim 1 or 2, in which the TPU layer (11) is a TPU foil.
4. Method according to any of the preceding claims in which the upper side (2) or underside (6) of the foam plastic shoe insole blank (1), which is to participate in an ironing process comprises a release agent remaining from the foaming process.
5. Method according to any of the preceding claims, in which the covering (10) is made of Alcantara, leather, textile, fleece, fur, and/or any other conventional covering material for foam plastic shoe insoles.
6. Method according to any of the preceding claims, in which the foam plastic shoe insole blank (1) has been produced from PU foam, in particular in the RIM process.
7. Method according to any of the preceding claims, in which the foam plastic shoe insole blank (1) has been produced from EVA foam.
8. Method according to any of the preceding claims, in which the foam plastic shoe insole blank (1) has been produced from a plurality of foam plastic materials which have different hardness values.
9. Method according to any of the preceding claims, in which the foam plastic shoe insole blank (1) comprises a core part (9) to which foam has been applied.
10. Method according to Claim 9, in which an external side of the core part (9) to which foam has been applied is visible at the underside (6) of the foam plastic shoe insole blank (1) and at least to some extent forms the underside (6) of the foam plastic shoe insole blank (1).
11. Method according to Claim 9 or 10, in which the core part (9) comprises a recess in a heel region (5) which is filled with foam plastic (7).

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