JP3016166B2 - Embossed sheet, method for producing the same, and shoe sole using the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[Object of the invention]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an embossed sheet provided with anti-slip projections, such as a shoe sole of athletic shoes, a method of manufacturing the same, and a shoe sole to which the embossed sheet is applied.

[0002]

BACKGROUND OF THE INVENTION In recent years, especially in marathon shoes and jogging shoes, in order to reduce the weight of the shoes and to absorb shock, the bottom of the contact surface is formed of solid rubber or high-density sponge. A shoe sole having a so-called multiple structure in which one or a plurality of sponges such as EVA (ethylene vinyl acetate), which are excellent in quality, are superimposed. However, in order to improve the gripping force and abrasion resistance of the anti-slip projection provided on the bottom of the tread, a solid rubber or a high-density sponge having a high hardness is used, so that the shoes are inevitably used. There was a drawback that weight reduction had a limit.

[0003] For this reason, Japanese Patent Application No. 63-140729 discloses a method in which a polyurethane resin film on a non-woven fabric sheet and a liquid polyurethane compound before formation of anti-slip projections are heat-cured by a mold and integrally joined. JP-A 1-3106
No. 01 gazette), whereby the sole of the shoe has been made as thin and light as possible as long as the anti-slip projection does not wear out early and lose its slip resistance.

However, even with this improved method,
When filling the mold with the liquid polyurethane compound, it is necessary to remove excess liquid polyurethane compound, which is called leveling. Since the nonwoven fabric sheet that easily absorbs water is used as the bottom surface of the ground surface, there is a drawback that the sheet absorbs water during rainfall and becomes heavy.

[0005] In addition, there are many things in the world, including grips for rackets, cameras, handles, and the like, which are provided with anti-slip projections that are gripped with palms or that suppress movement due to mutual friction between other parts. There is a need for an embossed sheet that is not limited to a sole but requires anti-slip properties and abrasion resistance and that does not absorb water even during rainfall.

[0006]

[Technical matters attempted to be developed] The present invention has been made in view of such a background, and does not require the leveling work as described above, and has a water absorbing property by forming a base film into a solid film. It is intended to provide a method for forming an emboss which is formed in a thin layer without any problem, has high anti-slip properties, and has abrasion resistance. Further, the embossed sheet thus obtained is applied to the midsole as an outer sole to provide a truly lightweight shoe sole that has no water absorption, has a ground gripping force, and has abrasion resistance.

[0007]

Configuration of the Invention

That is, an embossed sheet according to the first invention of the present application is obtained by printing an embossed pattern with a thermosetting resin ink on a nonwoven fabric sheet made of a thermoplastic resin fiber, and applying heat and pressure. A non-slip projection formed on the embossed pattern portion, and a solid film portion formed by heat-sealing a nonwoven fabric into a thin film portion on a portion other than the embossed pattern. .

[0008] The method for producing an embossed sheet according to the second invention of the present application is a method for printing an appropriate embossed pattern on a nonwoven fabric sheet made of thermoplastic resin fibers using an ink made of a thermosetting resin. The non-woven fabric sheet is sandwiched between the upper and lower molds with the embossed pattern corresponding to the recess formed in one of the pair of upper and lower molds, and the non-woven fabric sheet is heated and pressed to cure the ink constituting the embossed pattern. In addition, the non-woven fabric sheet sandwiched between the flat portions of the pair of molds is formed into a solid film.

[0009] Further, according to a third invention, a method of manufacturing an embossed sheet according to the present invention, in addition to the requirement of the second aspect, the nonwoven fabric sheet made of the thermoplastic resin fiber and the ink made of the thermosetting resin are used. The embossed pattern is a non-slip protruded pattern on a shoe sole, each of which is made of a polyurethane-based composition.

A shoe sole according to a fourth aspect of the present invention is a shoe sole comprising an outer sole having an embossed projection formed on a midsole, wherein the outer sole is made of a thermoplastic material. A non-woven fabric sheet made of resin fibers is heat-fused to form a thin solid film, and a non-slip projection formed by curing an ink made of a thermosetting resin is formed on the surface thereof. It is. Accordingly, the object is achieved.

[0011]

According to the present invention, the ink composed of the thermosetting resin printed on the embossed pattern is thermoset by the application of heat and pressure by the upper and lower molds, while the thermoplastic resin as the base on which the ink is printed is formed. The nonwoven sheet of resin fiber melts,
They are fused to each other to change into an integrated solid film, and as a result, embossed projections are formed on the sheet formed into a solid film.

When the printed ink is present only on the surface of the nonwoven fabric, a thin emboss is formed on the surface of the nonwoven fabric by heating, while when the ink is impregnated deeply into the nonwoven fabric, a certain amount of heat is applied by heating. An emboss having a thickness is formed.

Further, after printing an ink made of a thermosetting resin on the anti-slip pattern on the sole of the shoe, an embossed sheet is obtained by the same method, and the sheet is attached to the mid sole as an outer sole. The present invention provides a lightweight shoe sole that has no water absorption, has a ground gripping force, and has abrasion resistance.

Further, the shoe sole according to the present invention is lightweight and flexible since the nonwoven fabric sheet is a thin layer made of a solid film, and can effectively exert the ground gripping force of the polyurethane elastomer projections. The polyurethane elastomer projections are heat-cured together with the non-woven fabric sheet and are integrally bonded, so that the bonding between the two is strong and there is no possibility that the projections will be missing due to a landing impact in running.

[0015]

Next, the embossed sheet of the present invention and a method for producing the same will be described as an outer sole for a shoe sole and a method for producing the same. FIG. 1 shows an athletic shoe 1 having an outer sole using the embossed sheet according to the present invention, which comprises a midsole 3 at the bottom of a shoe body 2 and an outer sole 4 underneath. This outer sole 4
Is an application of the embossed sheet of the present invention, in which an embossed anti-slip projection 5 is formed and a thin solid film portion 6 is formed in other smooth portions.

Next, a method for manufacturing such an outer sole 4 will be described with reference to FIGS. In FIG. 3, reference numeral 7 denotes a non-woven fabric sheet made of thermoplastic resin fibers. In this embodiment, a melt-blowing method (Melt-blow method), which is a kind of a so-called jet spinning method, in which long fibers of a polyurethane resin are self-bonded. −
(Blowing) is used. Examples of this kind of commercially available nonwoven fabric include Tapyls (TAPYRUS-registered trademark) sold by Tonen Tapils.

Reference numeral 8 denotes a screen printing plate used to form a pattern of a non-slip projection on the sole of the shoe. Printing can be performed on the nonwoven fabric sheet 7. As described later, since the viscosity of the ink composed of the thermosetting resin is high, the mesh is preferably coarse.

In the method of manufacturing an embossed sheet according to the present invention, it is preferable to use a thick printing means, for example, screen printing, intaglio printing, octopus printing, and the like. In addition, when the thickness of the ink is thin in one printing, the ink may be overprinted, and in this case, after printing, suction is performed from the side opposite to the printing surface, and the method of printing again is repeated, and the thickness is increased. It may be printed. When printing is performed in a superimposed manner, multicolor printing can be performed by changing the printing plate.

Further, as shown in FIG. 4, reference numeral 9 denotes an upper mold in which a reverse pattern of the pattern of the anti-slip projection 5 on the shoe sole is engraved, and a recess 10 is formed in a portion where the anti-slip projection 5 is formed. The portion which is engraved and does not form the anti-slip projection forms a flat portion 11, and the recessed portion 10 and the flat portion 11 are adjacent to each other to form a pattern opposite to the anti-slip projection as a whole. .

Further, reference numeral 12 denotes a lower die which is paired with the upper die 9, and in this embodiment, is constituted by a flat plate. The upper mold 9 and the lower mold 12 may be reversed, or the upper mold 9 and the lower mold 12 may have the recessed portions 1 respectively.
0 may be formed, and the embossed pattern of the anti-slip projection may be formed by a combination of both molds. The upper mold 9 and the lower mold 12 are disposed between a base 16 of a heat press 15 having a heating means and a pressing means (not shown) and a pressing plate 17 and heated and clamped therebetween. It has become so. In addition, as a heating means, an appropriate means such as a high frequency wave, an ultrasonic wave, and a microwave can be selected in addition to a heat press machine.

Next, the procedure of the method will be described. First, as shown in FIG.
An ink 18 made of a thermosetting resin is screen-printed on the nonwoven fabric sheet 7 made of a thermoplastic resin fiber. In the present embodiment, the ink 18 made of a thermosetting resin used here is a polyurethane resin-based one in accordance with the fact that the nonwoven fabric sheet 7 is a polyurethane resin-based one. Specifically, an isocyanate polymer mixed with an appropriate coloring pigment and heated to 50 to 150 ° C. and a curing agent and a catalyst heated to 80 to 130 ° C. are both uniformly mixed. After stirring, defoaming ink of a two-component polyurethane composition is used.

By screen printing in this manner, the thermosetting resin is applied on the nonwoven fabric sheet 7 of the thermoplastic resin fiber by the ink pressure corresponding to the ink viscosity or the mesh of the screen printing plate 8 or the like. A non-slip pattern 19 on the sole of the shoe is adhered by the ink 18 consisting of still,
A masking agent such as silicone oil may be applied to the outside of the embossed pattern in order to set up (cut off) the edge of the pattern. Further, as one method of increasing the thickness of the ink 18, a method of performing overprinting may be employed. In this case, it is possible to repeatedly perform the operation of sucking the ink 18 from the surface opposite to the printing surface and then performing the next printing so that the ink 18 can be impregnated into the nonwoven fabric sheet 7 efficiently.

Next, as shown in FIG. 4, the non-slip pattern 19 on the non-woven fabric sheet 7 is made to correspond to the concave portion 10 of the upper mold 9, and the lower mold 12 is pressed from the opposite side. 7 is sandwiched between the upper mold 9 and the lower mold 12, which is disposed between the base 16 of the heat press 15 and the pressing plate 17, and from this state, the liquid polyurethane compound in the mold hardens. Pressurize and heat at a pressure of 150 kg / cm ² and a temperature of about 50 to 150 ° C. for about 1.5 to 2 hours.

At this time, when the non-woven fabric sheet 7 is heated and pressurized via the upper and lower molds 9 and 12, the ink 18 made of the thermosetting resin on the non-woven fabric sheet 7 is thermoset, and
Since the nonwoven fabric sheet 7 itself is also pressed by the flat portion 11, the thermoplastic resin fibers are melted and fused together at the same time to form one thin solid film, whereby the solid film portion 6 is formed. . Then, after lowering from the heat press machine 15 and removing the upper and lower molds 9 and 12, it is further heated at a temperature of about 50 to 150 ° C. for about 1 hour to 1 hour.
Aging is performed for 0 hours. Thereby, an embossed sheet is obtained.

If the depth of the recess 10 is set to be equal to or less than the sum of the thickness of the nonwoven fabric sheet 7 when the non-woven sheet 7 is formed into a solid film and the height when the ink 18 is thermally cured, the ink 1
The lower layer to which 8 is attached also becomes a solid film and becomes strong. If the depth of the recess 10 is not less than the total, the formation of a solid film in the lower layer to which the ink 18 has adhered is uncertain. Although inferior in quality, an embossed sheet having a cushioning property is obtained. At this time,
If a high-pressure non-woven fabric sheet is used and a strong pressure is applied, the thermoplastic synthetic resin that has melted in the adjacent flat portion 11 partially flows into the recessed portion 10 and the emboss is formed to be higher than the ink pressure. Is also possible.

[0026] Upon curing the other hand the ink 18, the positional relationship between Lee <br/> ink 18 and the nonwoven fabric sheet 7, the ink 18
If the suction of the ink is not performed, the ink 18
There are three possible modes, that is, only when the ink 18 is present only on the surface of the nonwoven fabric sheet 7, when the ink 18 partially enters the nonwoven fabric sheet 7, and when the entire ink 18 enters the nonwoven fabric sheet 7. Ink 1 for such a nonwoven fabric sheet 7
Penetration aspects of 8, standing Oh the formation of slip protrusions 5, its thickness are those large influence on the strength or the like, is greater relates also to the depth of the recess 10 in the upper mold 9.

That is, if the recess 10 of the upper mold 9 is set deep as shown in FIG. 6A, the ink 18 is hardly pushed in, so that the ink 18 exists on the surface of the nonwoven fabric sheet 7. . Further, if the recess 10 is set to be shallow to some extent as shown in FIG. 6B, a part of the ink 18 penetrates into the inside of the nonwoven fabric sheet 7 and the recess 10 is further formed as shown in FIG. If it is set shallow, all of the ink 18 will penetrate into the nonwoven fabric sheet 7. Incidentally, the infiltration of the ink 18 into the nonwoven fabric sheet 7 can be performed by suctioning the ink 18 from the opposite side of the printing surface as described above.
It is better to make adjustments with the setting of the depth of the delicate adjustment.

The embossed sheet 7 thus obtained
a is cut into the shape of a shoe sole as shown in FIGS.
By attaching an appropriate adhesive to the midsole as the outer sole, or by in-molding this at the time of foam molding or the like of the midsole portion, the sole can be used as the sole of the ground surface of the shoe sole. In addition, the shoe sole obtained in this manner is lightweight as it is applied as a shoe sole for marathon shoes, jogging shoes, etc., has slip resistance and abrasion resistance, has no water absorption, and has no water absorption even during rainfall. Absorbs and gets heavy shoes. EVA, urethane rubber, RB,
A shoe sole with a high cushioning property can be obtained by using the midsole of a foamed elastomer such as polyethylene or PVC.

Further, since the anti-slip projection pattern is formed by the printing means, various colors and patterns of the non-woven fabric sheet and the anti-slip projection can be appropriately adopted, and a ground contact bottom having a novel design which is not available in conventional products. Can be provided. By the way, as a method of changing the color and the color pattern, it is possible to repeat the work of sucking the previously printed ink 18 from the opposite surface side of the nonwoven fabric sheet 7 and then changing the plate and printing another color ink. Good. In this case, it is sufficient to prepare as many printing plates as the number of color types and prepare one type of mold.

In the above embodiment, a polyurethane-based non-woven fabric sheet made of a thermoplastic resin was used as a raw material.
Also, a polyurethane-based ink was used for the ink composed of the thermosetting resin. However, as a raw material of the non-woven fabric sheet of the thermoplastic resin fiber, a hydrocarbon-based resin such as polyethylene, polypropylene, and polybutadiene, polyvinyl chloride, and polyvinyl chloride were used. It can be selected from vinyl resins such as vinylidene, polyvinyl alcohol, etc., other linear structural resins such as polyamide 6, polyamide 66, polycarbonate, polyimide, etc., and cellulose resins such as cellulose acetate, and also comprises thermosetting resins. As the ink, phenolic resin, urea resin, melamine resin, furan resin, silicone resin, ethoxy resin, unsaturated polyester resin, acrylic resin, etc. can be selected as the main raw material. Modified even if thermoplastic or thermosetting Allowed, or the like to the composite, of course may be made of a thermosetting or thermoplastic.

Further, even in the spinning method of these synthetic resins,
In addition to the melt spinning of the examples, regardless of polymerization spinning, a dry method, a wet method, etc., the method can be appropriately selected from the balance with the raw material of the synthetic resin to be spun and applied. Although the above embodiment employs a means for printing an embossed pattern, it is also possible to adopt a method in which all the ink is impregnated into a nonwoven fabric and the emboss is formed by a mold.

[0032]

As described above, according to the present invention, even the leveling work of the method which has been conventionally improved is unnecessary, and the obtained embossed sheet has a solid film at its base, It has no water absorption, is formed in a thin layer, and has a slip resistant projection with high slip resistance and abrasion resistance. Further, by using the embossed sheet as an outer sole, water absorption no, there is ground grip, wear resistance there can be provided as the sole truly is lightweight.

[Brief description of the drawings]

FIG. 1 is a partially exploded perspective view showing an athletic shoe provided with an outer sole using an embossed sheet of the present invention.

FIG. 2 is a bottom view showing an outer sole using the embossed sheet of the present invention.

FIG. 3 is a perspective view and a skeletal longitudinal sectional view showing a printing process.

FIG. 4 is a perspective view and a skeleton longitudinal sectional view showing a pressing step.

FIG. 5 is a perspective view showing a punching step of forming an embossed sheet into a shoe sole.

FIG. 6 is a skeletal explanatory view showing how the degree of penetration of ink into the nonwoven fabric sheet changes depending on the depth of the concave portion of the upper mold.

[Description of Signs] 1 Athletic shoes 2 Shoe body 3 Midsole 4 Outer sole 5 Non-slip projection 6 Solid film part 7 Nonwoven fabric sheet 7a Embossed sheet 8 Screen printing plate 9 Upper mold 10 Recessed part 11 Flat part 12 Lower mold 15 Heat press machine 16 Base 17 Pressing plate 18 Ink 19 Non-slip pattern

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-1-310601 (JP, A) JP-A-2-125608 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 A43B 1/00-23/30

Claims (4)

(57) [Claims] 1. A non-woven sheet made of a thermoplastic resin fiber, on which an embossed pattern printed with an ink made of a thermosetting resin is heated and pressed to form non-slip projections on the embossed pattern portion. An embossed sheet characterized in that a non-woven fabric is heat-fused to form a solid film portion thinned to a portion other than the embossed pattern. 2. An appropriate embossed pattern is printed on a non-woven fabric sheet made of thermoplastic resin fibers using an ink made of a thermosetting resin, and then the embossed pattern is formed on one of a pair of upper and lower molds. In a state corresponding to the recessed portion, the nonwoven fabric sheet was sandwiched between upper and lower molds, and heated and pressed to cure the ink constituting the embossed pattern, and was sandwiched between the flat portions of the pair of molds. A method for producing an embossed sheet, comprising forming a non-woven sheet into a solid film. 3. The nonwoven fabric sheet made of thermoplastic resin fibers and the ink made of thermosetting resin are each made of a polyurethane-based composition, and the embossed pattern is made of a non-slip shoe sole. 3. The method for producing an embossed sheet according to claim 2, wherein the embossed sheet has a projection pattern. 4. A shoe sole comprising an outer sole having an embossed projection formed on a midsole, wherein a non-woven fabric sheet made of thermoplastic resin fibers is heat-sealed to the outer sole. A shoe sole comprising a thin layered solid film formed thereon, and a non-slip projection formed by curing an ink made of a thermosetting resin on the surface thereof.