1

DEFINITION OF MICROCELLULAR & SPONGE PRODUCTS

1. MICROCELLULAR PRODUCTS HAVE SUBSTANTIALLY CLOSED CELLULAR STRUCTURE - HAVING INDIVIDUAL CELL WALL WHEREAS 2. SPONGE RUBBER HAS OPEN OR INTERCONNECTING STRUCTURE.

TYPES OF CELLULAR RUBBER

1. EXPANDED RUBBER 2. MICROCELLULAR PRODUCT 3. SPONGE RUBBER

2.

TYPES OF MICROCELLULAR SOLING

I. II. III.

SOFT MICROCELLULAR SOLING FOR HAWAI OR BEACH SLIPPERS. MEDIUM HARD MICRO CELLULAR FOR LEATHERS TOP CHAPPALS. HARD MICROCELLULAR SOLING FOR LEATHER SHOES

SOME CHARACTERISTICS OF THESE SOLES ARE AS FOLLOWS.

CATEGORY SHORE A

APPROX DENSITY

APPROX HARDNESS 3 - !"

HAWAI / BEACH SLIPPER

.3- .!

MED. HARD MICRO SOLING

." .#

"" - #"

HARD MICRO SOLING

.$- .%

$ -%

HAWAI SLIPPERS&
ORGINALLY THESE SLIPPERS WERE MEANT FOR USING ON BEACHES OR INDOOR BECAUSE OF THEIR LOW COST THESE CHAPPALS HAVE BECOME VERY POPULAR AMOUNGST THE POOR POPULATION WHO USE IT AS ALL PURPOSE FOOTWEAR.

MEDIUM HARD MICRO SOLING

GENERALLY USED FOR LEATHER OR RESIN UPPER CHAPPALS. THESE ARE VERY MUCH IN HIGH DEMAND FOR FASHION CONSCIOUS URBAN PEOPLE WHO NEED MORE ELEGANT AND LIGHT WEIGHT FOOTWEAR THEN LEATHER SOLE CHAPPAL.

HARD MICRO SOLING

THIS SUPERIOR PERFORMANCE SOLING MATERIAL IS GENERALLY USED FOR LIGHT WEAR AND HEAVY DUTY SHOE SOLES BECAUSE OF ITS LIGHT WEIGHT AND BETTER WEAR RESISTANCE. THE 'UALITY OF MICROCELLULAR MATERIAL CAN BE (UDGED FROM& A. B. C. D. E. DENSITY HARDNESS SPLIT TEAR RESISTANCE SHRIN)AGE CONTROL FLEX RESISTANCE

4.

METHODS OF MANUFACTURING MICROCELLULAR SOLE

A.

PRODUCED FROM RUBBER COMPOUND CONTAINING ORGANIC BLOWING AGENT. MOULDING BY COMPRESSION MOULDING SYSTEM. MOULD FILLED WITH COMPOUND 3* EXCESS IN VOLUME MOULDING AT HIGH PRESSURE IN A HYDRAULIC PRESS TEMP NORMALLY 1!" 1"" DEGREE C PRECURED SHEETS ARE FOLLOWED BY POST CURING IN A CHAMBER +HOT AIR CURE, AT 1 DEGREE C FOR 3-! HRS.

B. C. D. E. F.

5.

PHYSICAL RE'UIREMENT FOR MICROCELLULAR RUBBER SHEETS

TYPE-1 I. II III RELATIVE DENSITY HARDNESS IRHD- MIN. CHANGE IN HARDNESS AFTER AGEING AT 1 1 1 D./0.. C FOR 2! HRS. COMPRESSION SET AT 2$ 1 1 D./0.. C FOR 2! HRS.- * MAX. SPLIT TEAR STRENGTH )G. MIN. HEAT SHRIN)AGE AT 1 D./0.. C FOR 1 HOUR IN BOTH DIRECTIONS* MAX. WATER ABSORPTION- * BY MASS- MAX. .# - .$ #" D./0.. 1" TO TYPE-2 .!"- ."" " D./0.. 1" TO -

IV

12

1"

V VI

%. 2

#. 3

VII

1."

2.

6.

PHYSICAL RE'UIREMENT FOR STANDARD 'UALITY HAWAI SOLE

I. II. III. RELATIVE DENSITY HARDNESS IRHD CHANGE IN HARDNESS AFTER AGEING AT 1 1 1 2./0.. C FOR 2! HRS. COMPRESSION SET AT 27 1 1 D./0.. C FOR 2! HRS. * MAX SPLIT TEAR STRENGTH- 3/. ROOM TEMPERATURE SHRIN)AGE AT 2$ 1 1 2./0.. C FOR ! WEE)S- * MAX. .3- .# !" 2./0..-" 2./0.. 1 "- -

IV.

15

V. VI.

!-" 1. 2.

VII. FLEX RESISTANCE- NUMBER OF CYCLES ROSS FLEX TESTING MACHINE A. INITIAL CRAC)- MIN. B. # * CUT GROWTH ! # # 1 -

PHYSICAL RE'UIREMENT FOR STANDARD HAWAI STRAP

I.
II. III. IV.

RELATIVE DENSITY TENSILE STRENGHT, kg /cm2 EL NGATI N, ! HARDNESS IRHD #HANGE IN INITIAL HARDNESS A$TER A##ELERATED AGEING $ R 24 H %RS AT 100 " 1 &'g('' # $LE) RESISTAN#E N%*+ER $ #Y#LES N R SS $LE) TESTER A. INITIAL #RA#,S +. 600! #%T GR .TH

1.3 1.4 150-160 400-500 60 " 5 "5 T -5

VI.

60,000--5,000 100,000-130,000 30-45

VII. TEAR STRENGTH, kg. / cm2

RECIPE RUBBER MICROCELLULAR SOLE

INGREDIENTS NR HSR WOOD ROSIN 5INC OXIDE STEARIC ACID ANTI OXIDANT VALCAFOR F MBTS PROCESS OIL SALICYLIC ACID PPT. SILICA ALUM. SILICATE HARD CLAY SULPHUR DNPT COLOUR MICROCELLULAR CRUMB PBW )/4. # . ! . 2. ! ". ! ". 1. .% .3 ". ." 1 . 2 3 . # $ . 2." # $. AS. RE'D. $ % .

CURE $ % MINUTE AT 1"" 1# D./0.. C. PROPERTIES& DENSITY .!" ." HARDNESS !% " IRHD SPLIT TEAR - 3." !. 3/4. SHRIN)AGE +OVEN, 1." *

TYPICAL FORMULATION MICRO COMPOUND INGREDIENTS R*A S+R 1/5S+R 1502 R+ -20 0IN# )IDE STEARI# A#ID 1HEN LI# ANTI )IDANT SILI#A AL%*INI%* SILI#ATE #HINA #LAY *I#R #R%*+ 1ETR LE%* 2ELLY 1R #ESS IL . D R SIN DEG TITANI%* DI )IDE S%L1H%R *+TS $ T*T +L .ING AGENT 3DN1T4 RGANI# # L %R #%RED AT 150 &'g('' # DENSITY HARDNESS SH RE A D'g. S1LIT TEAR STRENGTH ,g. / cm 2 ! SHRIN,AGE R SE $LE) TEST #RA#, INITIATI N, ,# 'UANTITY 20.0 20.0 60.0 10.0 20.0 70.0 4.0 6.0 5.0 5.0 1.0 1.0 20.0 40.0 70.0 50.0 5.0 10.0 4.0 2.0 5.0 2.2 1.2 0.1 5.0 56 ('7&. 6.0 0.5 620.0 4.0 1.50 35.0 20.0 35.0 50.0 5.0 5.0 4.0 2.0 5.0 1.5 1.4 5.0 56 ('7&. 12.0 0.4 500.0 3.0 2.0 45.0

10

RECIPE STRAP COMPOUNDS INGREDIENTS R*A 0IN# )IDE STEARI# A#ID 1HEN LI# ANTI )IDANT AL%*INI%* SILI#ATE 11TD. #AL#I%* #AR+ INATE #HINA #LAY 1ETR LE%* 2ELLY #I RESIN DEG TITANI%* DI )IDE *+TS T*T S%L1H%R SANT GARD 1VI-50 #%RED AT 150 D'g. # 3*4 S1E#I$I# GRAVITY TENSILE STRENGTH, kg / cm2 EL NGATI N AT +REA, ! 300! * D%LS, kg / cm2 ANG%LAR TEAR STRENGTH, ,g / cm2 HARDNESS SH RE 8A9 'UANTITY 100.0 6.0 1.50 1.00 30.00 30.00 30.00 6.00 2.00 1.00 5.00 1.20 0.20 1.-0 0.25 4 1.37 170 430 65 27 54

11

TESTING OF MICROCELLULAR SOLING SOLE PARAMETERS 1. DENSITY 3gm6. cc4 2. HARDNESS-3IRHD4 3. S1LIT TEAR-kg6. 4. THI#,NESS 3m /m4 4. THI#,NESS 4m/m4 5. $LE)I+ILITY 3R SS-#Y#LES4 6. SHRIN,AGE-! VEN 1:(6. AT 100 D'g('' # R * TE*1. 60 D'g('' #-1 :(6. EVA 7. # *1RESSI N SET 3!4 1. S1. GRAVITY 2. HARDNESS 3. TEAR STRENGTH 3kg64 STRAPS

12

EVA MICROCELLULAR

VARIOUS USE OF EVA MICROCULLULAR IN FOOTWAR INDUSTRY 1. 2. 3. 4. 5. 6. AS S LING *ATERIAL AS *IDS LE 32 GGER TY1E SH E4 INS LING *ATERIAL 3* %LDED4 LA*INATED INS LE %11ER *ATERIAL $ R SANDALS VARI %S THER* $ R*ED # *1 NENTS

13

EVA MICRO SOLING PROPERTIES A. VERY LIGHT & COMFORTABLE PRODUCT POSSIBLE B. NO ROOM TEMP. SHRIN)AGE C. NO POST TEMPERING & STORAGE D. RE'UIRED PHYSICALS FOR MICRO SOLING ACHIEVABLE. E. BRIGHT & ATTRACTIVE COLOUR POSSIBLE

14

PHYSICAL PROPERTIS EVA SOLING

PROPERTIES 1. DENSITY +/6/77, 2. HARDNESS +IRHD, 3. SPLIT TEAR 3/4. +2." 76 W829: 9.49 ;8.7., !. SHRIN)AGE OVEN +*, A. AT # 2./0.. C. 1 :04. B. ROOM TEMP. 1 <3. ". COMPRESSION SET +*, % BEACH SANDAL .2 .2" 2" 3 3" ! 2." 3. SHOE SOLING .3" .! " "" ".

1. ." =8>

." =8> $

15

BASIC DESIGNING OF COMPOUND

A.

EVA COPOLYMER CROSS LIN)ING AGENT BLOWING AGENT ACTIVATOR LUBRICANT

B. C. D. E.

OTHER COMMON INGREDIENTS

I.

INORGANIC FILLER PIGMENT POLYMER MODIFIER MICRO WASTE +EVA,

II. III. IV.

16

EVA SOLE RECIPE +TYPICAL,

INGRIDIENTS 1. EVA +1# 1% * VA, 2. HIGH STYRENE RESIN 3. A5O TYPE BLOWING AGENT +ADCL, !. DCP ? * ". 5INC OXIDE #. STEARIC ACID $. %. ?. PPT. CAL. CARB. PIGMENTS EVA CRUMB %. 1. 1. 1. 3 . AS RE'D. 1 2 . BEACH SANDAL 1 . -LEATHER SHOES SOLING $ . 3 . ". 1.3 1. 1. 3 ! . AS RE'D. 2 3 .

17

EVA MOULDING
1. TIME 2. TEMP. 13 1" MINS. +1" 6/6 THIC) SHEET, 1# 1#" D./0.. C. 1" 2 3/ / 76 4@.

3. HYD. PRESSURE !. LOADING -

." 1* EXCESS

1. 'UIC) OPENING PRESS +# 1 S.7.,

MOULD
A. THE EDGE OF THE MOULD MUST BE PROVIDED WITH A GENEROUS TAPER +!" 2./0.. ANGLE, B. THE TAPERED SECTION SHOULD BE SMOOTH. C. THE PRESS MUST OPEN VERY RAPIDLY +1 76 / 4.7, M8=86A6. D. THE ENTIRE SURFACE OF THE MOULD MUST BE SPREAD WITH MOULD RELEASING AGENT.

1/

RECENT POLYMER BLENDS POLYMERS 1. NR " S+R " HSR CURE S%L1H%R FEATURES # NV. #%RING 1 ST #%RING ; ST RAGE RE<D. L . SHRIN,AGE N . 1 ST. #%RING N . SHRIN,AGE N . 1 ST #%RE N . ST RAGE = N 1 ST #%RE N . SHRIN,AGE * %LDING 1R +LE* SATI$A#T RY <%ALITY A#HIEVA+LE

2. 3.

NR " HSR " EVA NR. " 1E

1ER )IDE =

4. 5.

NR " LD1E " EVA 1V# " NITRILE

= S%L1H R

6.

LD1E " NR " HSR

S%L1H R

20

SHRIN)AGE CONTROL OF MICROCELLULAR PRODUCTS

1.

BY USING SUITABLE POLYMER OR BLEND OF POLYMERS BY USING APPROPRIATE REINFORCING FILLER BY PROPER PROCESSING METHODS B. C. 7. .. SUFFICIENT MASTICATION STORAGE AFTER MIXING AND SHEETING STAGE CURING STORAGE AFTER CURING

2. 3.