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Lianbang injection: automatic production process of anti-smashing shoes

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Lianbang injection: automatic production process of anti-smashing shoes

Release date:2018-03-10 Author: Click:

Smash shoes

Anti-smashing shoes belong to a profitable market with a relatively small but special professional footwear market. Covering a variety of shoes, the world's annual shoe production will be nearly 20 billion pairs, and most of these are handmade shoes, a time-consuming and error-ridden approach. At present, only 10% of the manufacturers use fully automatic or semi-automatic production lines, and the degree of automation in other industries is significantly higher, which is a trend that footwear producers cannot ignore. Some large shoe manufacturers have realized the benefits and necessity of automated footwear.

Anti-smashing shoes belong to a profitable market with a relatively small but special professional footwear market. Covering a variety of shoes, the world's annual shoe production will be nearly 20 billion pairs, and most of these are handmade shoes, a time-consuming and error-ridden approach. At present, only 10% of the manufacturers use fully automatic or semi-automatic production lines, and the degree of automation in other industries is significantly higher, which is a trend that footwear producers cannot ignore. Some large shoe manufacturers have realized the benefits and necessity of automated footwear.

Demand for anti-smash shoes is showing a continuous increase. There are a number of reasons for this: the increased awareness of safety; the development of more regulations on health and safety in working areas; the increasing degree of industrialization in developing and near-developed countries, and the growing population and urbanization process. The latter two factors occupy the dominant position. According to the DSW (German World Population Foundation) statistics, there are currently a total population of approximately 7.1 billion people on Earth. By 2050 this number is expected to grow to 9.6 billion. More than 50% of the world’s population now lives in cities, and by 2050 this percentage may increase to 80%. The population of big cities has exceeded 20 million people. In order to provide such a huge city with a functional infrastructure that provides food, water and energy, huge industrial demand is essential. And the demand for personal safety equipment from these industrial workers has also increased.

Anti-smashing shoes are high-tech products

Anti-hit shoes must meet the highest requirements for consistent, consistent production quality. This requirement can only be achieved through an efficient and automated safe and controllable production process. Anti-hit shoes surface materials usually include wear-resistant leather, anti-slip material such as polyurethane (PU or PUR), rubber (GU) or thermoplastic polyurethane (TPU). Built-in protective toe caps made of steel, aluminium or composites prevent toe injuries. Permeability protection made of steel, composite material or aluminum prevents nails or other sharp objects from being inserted into the foot. In addition, modern shock absorption makes the wearer more comfortable. Sole production is a major and decisive production link that is independent of the type and use of anti-smash shoes and is about quality and safety. This is where Desimar Lianjian Injection Machine is to be shown to everyone.

Lianbang Injection - Never Compromise Quality Assurance

The first execution of the machine-injection injection by the machine was born in 1953, when the shoes factory workers used the manual vulcanization button. They place rubber strips or slabs in open shoe sole molds and press them onto the frame with the upper. In the next few years, automation has undergone rapid development. In 1960, DESMA will formally deploy two to ten workstations, and side-mounted disc machines with automatic injection injection units will be introduced into the market. At this point, labor-intensive and inaccurate methods of manually applying adhesive to the soles of shoes have gradually become obsolete. The working principle of the developed machine has been used up to now. The injection casting unit plasticizes the preformed sole material such as rubber strips or plastic granules, and then injects the raw material liquid into the opened sole mold. Then, the metal frame covering the upper is lowered to a certain depth in the sole mold, so that the upper and the sole mold cavity form a complete combined state. The sole, which is still liquid in the mould cavity, solidifies on the upper while forming a special form. This way of gang injection machine brought a brand-new revolution to footwear production. It brings an efficient automated device production line, increasing the production of shoes, and also reducing the corresponding losses in the production process. However, the production process before and after the injection of the rifampies still needs to be completed manually. Further research and development has brought about more productive and more flexible machine components. The application of industrial robots has replaced the mistaken artificial activities. For example: release agent applications that facilitate shaping of the sole prior to filling and roughing of the upper before bolus injection.

With the continuous update of the automation of the DESMA rotary machine, it is also the increase of the die unit. According to the demand of the process, the equipped assembly station can reach 18, 24, 30 or even 60. Nowadays, Deschma again presents the most advanced technical arts and crafts, multi-layer and multicolor automatic direct injection molding soles, as well as different sizes of production, sequence or material conversion, which can be within one rotation cycle of the disc machine. carry out. This flexibility provides users with great advantages in production, process, and economy. What's more important is that they can make timely response and adjustments to the requirements and can shorten the delivery time as much as possible.

In addition, due to the constant processing parameters, automated production guarantees stable product quality and satisfies the high standards of almost exacting zero error. Depending on the raw materials used in the sole, the procedure for the injection of the bolus also varies with the technical details. The most important raw materials used in soles today are mainly rubber (GU), thermoplastic polyurethane (TPU) and polyurethane (PU).

TPU and rubber injection

The rubber and TPU sole material is plasticized and filled into the open sole mould by DESMA's pouring technology DESflow®. The DESflow® casting process is a method of introducing the sole material into the mold, which saves material compared to the loss caused by precasting. Through the specified pouring speed and the use of various nozzles, the pouring time or the actual required rubber strip can be adjusted according to the specific size of the mold. In the plastic material is filled into the mold cavity, and the upper is also reduced to the raw material, the mold is closed. The sole material is tightly adhered to the upper under pressure. The mold opens again after the set processing time has elapsed. The disc machine rotates to the next process.

PU injection

PU injections are technically more focused and more complex. In this process, shoe manufacturers do not use pre-formulated raw materials, but instead produce raw materials that are produced when two or more liquid components undergo a chemical reaction (stepwise addition polymerization). In short, the two liquids must be mixed together at the beginning of the raw material, injected into the closed unit, and wait for the raw material to react to produce PU. Therefore, the raw material A is either a polyester or a polyether (polyhydroxy compound), and the raw material B is an isocyanate. Polyester polyol systems are more resistant to mechanical abrasion, high temperatures and chemical reactions than polyethers (polyols), which is why polyester polyols are more suitable for use in flood protection footwear.

The technical focus of the PU bolus injection is to precisely deliver, meter, mix, and inject the two reacted components into the mold cavity. Then the molded outsole is glued tightly along the edge of the silhouette of the upper. A hole is drilled on the surface of the mold above the mixing head of the injection unit to fill the nozzle at any time. Desma designed a special mixing head for this process.

In addition, a mechanically synchronized recirculation valve is located in the mixing head to deliver the liquid components at any time. The dispensing cycle valve opens and the liquid components to be mixed flow into the mixing chamber through the inlet channel. A conical screw for mixing and conveying ensures a single closed mix and is injected through the nozzle into the mold. The speed of the screw rotation can be continuously adjusted from 10,000 to 18,000 per minute. The screw and mixing chamber are cooled by the liquid to ensure constant temperature in the chamber. At the later stage of the mixing phase, the screw is oriented axially toward the nozzle, so that the amount of principle in the mixing chamber is greatly reduced. The purpose of this step is to help the self-cleaning of the set screw and chamber by the centrifugal force generated by the high-speed rotation of the screw, and the drip residue attached to the screw can be thrown onto the wall of the chamber.

The raw material is injected into the chamber to react and foam into a PU, and then adhered to the upper under pressure. The DESMA PU machine can also mix other additives and pigments. In addition, the user can also record recipes in the database that include production and processing parameters, which can then be assigned to the corresponding mold holders by either manual BAR code or RFID chip input during the exchange of the product or mold. . Therefore, it is necessary to ensure the correct parameters and stable production conditions in order to ensure that beautiful finished shoes are always available.

In the production of anti-smashing shoes, Lianbang injection technology is a mature, trustworthy manufacturing process. This technology has been successfully used worldwide. With the growing demand for stable quality of footwear and lower production costs, LianJin injection technology will win a big victory in the market. This application is particularly suitable for all kinds of lightweight and flexible shoes.


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