Omprakash H.

Nautiyal / International Journal of Engineering Science and Technology (IJEST)

Molding of EVA Soles Using Expanding

and Reducing Agents
Omprakash H. Nautiyal*
Alert India Pvt. Ltd., C-1, SMA Industrial Area, GT Karnal Road, New Delhi- 110033, India.
Email: opnautiyalus@yahoo.com; Cell: +91-0-9654355518
http://www.dropnautiyal.com

Abstract:
Selected polymers and polymer blends suitable for shoe sole manufacturing were processed by means of
compression and the shrinkage of standard square specimens was measured. The experimental work of which
was performed according to design of experiments techniques, aims to understand the influence of composition
and process factors, with the ultimate objective of mastering shrinkage control to a satisfactory degree. In the
case of compression molding, the polymer of choice was a reducing agent additive. Process conditions were
fixed and shrinkage control was obtained by subjecting the molded parts to thermal treatment at an appropriate
temperature. For the compression molding process, expanding and reducing agents and its blends with EVA
(ethylene vinyl acetate copolymer) were used. Here also, the process conditions were fixed; shrinkage was
controlled by an appropriate formulation of polymer compound and allowing shrinkage to be predicted. As all
this work was based on shop floor polymer specimens, setting up rules for real-world shoe sole manufacture is
beyond its scope. Nevertheless, the results obtained so far represent a sound experimental background for
evaluating the feasibility of further process developments.

Keywords: ERB 12065, EK-025, FRB, EVA, Cross link, Soles.

1. Introduction

We came across many technical problems on the shop floor while molding the EVA soles by compression, this
was due to small Mold size through which when the EVA was introduced then during de molding the soles were
big in size. This was the obvious tendency of EVA. This resulted in loss of the production. Expanding and
reducing agents were imported from China for studying its effect on controlling the compression of soles during
de molding. We set experiments with the various ratios of these agents. Our invention of varying the ratios of
agents to the EVA ratio gave quite interesting results. This has enabled the soles to retain their required size
during the curing process in curing chamber.

Ethylene vinyl acetate (also known as EVA) is the copolymer of ethylene and vinyl acetate. The weight percent
vinyl acetate usually varies from 10 to 40%, with the remainder being ethylene. It is a polymer that approaches
elastomeric materials in softness and flexibility, yet can be processed like other thermoplastics. The material has
good clarity and gloss, barrier properties, low-temperature toughness, stress-crack resistance, hot-melt adhesive
water proof properties, and resistance to UV radiation. EVA has little or no odor and is competitive with rubber
and vinyl products in many electrical applications. [Cassagnau et al. (1993)], [Bambara, et al. (1994)], [Yang,
(1994)]

EVA is one of the materials popularly known as expanded rubber or foam rubber. EVA foam is used as padding
in equipment for various sports such as ski boots, hockey, boxing, mixed martial arts, wakeboard boots, waterski
boots, fishing rods and fishing reel handles. It is typically used as a shock absorber in sports shoes, for example.
It is used for the manufacture of floats for commercial fishing gear such as purse seine (seine fishing) and
gillnets. In addition, because of its buoyancy, EVA has made its way into non-traditional products such as
floating eyewear. It is also used in the photovoltaic’s industry as an encapsulation material for silicon cells in the
manufacture of photovoltaic modules. EVA slippers and sandals are currently very popular because of their
properties like light weight, easy to mold, odorless, glossy finish, and cheaper compared to natural rubber. In
fishing rods, it is used to construct handles on the rod-butt end. EVA can be used as a substitute for cork in
many applications. [Cassagnau et al. (1993)], [Bambara, et al. (1994)], [Yang, (1994)]

P. Cassagnau have studied the trans esterification reaction in the molten state of ester groups of ethylene vinyl
acetate copolymers and ethylene acrylic ester copolymers, in the presence of dibutyltin oxide as a catalyst, leads

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to cross linking of the copolymer chains. The kinetics of this cross linking reaction has been assessed by two
different experimental methods: viscoelastic measurements of the dynamic storage modulus and thermo
gravimetric analysis coupled with gas chromatography which allows measurement of the evolved methyl acetate
which is a volatile product of the cross linking reaction. The equilibrium storage modulus calculated from
theories of elastic modulus has shown that the kinetics of the cross linking reaction may be determined through
variations of the dynamic storage modulus. [Cassagnau et al. {1993}]
The study for manufacturing the EVA soles was important issue for us and hence the expanding and reducing
agents; FRB, EK-025 and ERB 12065 were employed in the various ratios to optimize to get EVA soles with
perfect size as opening length. Our invention has shown to obtain the useful data for producing the soles.

2. Materials and methods

EVA, EK-025, ERB 12065 and FRB were imported from China, since these raw materials gave feasible costing
of the EVA soles. EVA compression machine was also imported from China and was able to produce 2500 pairs
per day.
EVA, EK-025, ERB and FRB were in the ratios of DOE was mixed in the hopper and was allowed to Mold and
de Mold. The barrel temperature was 82-85 o C, Mold temperature 174-175 o C, injection pressure 80-82 bar,
injection speed 22 rpm, duration time 12-16 seconds and curing time of 330-360 seconds.

2.1 Benn wart Flex Testing

The soles produced on the shop floor are sent to the quality evaluations. The first quality parameter is Flex
Testing where the soles are tightened at the both end and allowed to rotate at 90 o by putting a cut on the soles.
1, 00,000 cycles are run as a standard specification. During these cycles if the soles get cracked at the cut point
then the soles are rejected.

2.2 Tensile testing machine

The strip of the sole is tied at both the end and stretched by the machine unless it is broken from the centre. The
point, at which it breaks, is noted and the measure is matched to the standards.

2.3 Din Abrasion Testing

The soles are tested for the percent abrasion as per standard norms set by Bata and SATRA. The lesser the
measure of the abrasion the more is the life of the soles.

3. Results

ERB 12065 (L) and ERB (S) were varied as shown in the table 1. The soles produced with this ratio were
observed to be with cracks. They were hard and small. The wrinkles were also observed. The losses in the
weight were observed against the standard weight. The weight loss was 18, 17, 19 and 20 g. The large to small
ratio was 80:20 and 90:10. [Yang, (1994)], [Yang, (2002)], [Yung, Wun-bin, et al. (1996)]

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Table 1 ERB 12065 (L&S) ratio

EVA COMPOUND TRAIL (A)

Compound Code: ERB
12065 (L & S)

ARTICALE:- Judger Neel size- 190 mm

SIZE-: 08 Cavity size 197 mm
-

S.NO Trials Standard A B C D

1 BARREL TEMPERATURE 82 TO 85 85 85 85 85
0
C
2 MOLD TEMPERATURE 0C 174 - 175 175 175 175 175
3 INJECTION PRESSURE 80 TO 82 82 82 82 82
(BAR)
4 INJECTION SPEED 22 22 22 22 22

5 DURATION TIME (sec.) 12 TO 16 SEC 26 26 26 26

6 CURING TIME (sec.) 330 TO 350 SEC 360 360 360 360

7 OPENING LENGTH mm 335 215 290 320

8 ACTUAL LENGTH mm 292 205 260 280

9 SHRINKAGE IN mm 43 10 30 40

10 REQUIRED LENGTH mm 280 ~ 282 280 ~ 282 280 ~ 282 280 ~ 282 280 ~ 282

11 STD WEIGHT gm 220 220 220 220 220

12 ACTUAL WEIGHT gm 202 203 201 200

13 WEIGHT LOSS gm 18 17 19 20

14 Specific Observations Appearance Wrinkles Hard & Wrinkle , Cracks & Wrinkle , Cracks & Air
Small Air Bubble Bubble

15 Length Afrer 16 289 200 255 278

Hrs
16 Hardness After 16 23 63 33 25
Hrs

Sample A B C D
Description
ERB- 12065 (L) 3.000 0.000 2.000 4.500
Kg
ERB- 12065 (S) 0.000 3.000 0.500 5.000
Kg
L / S Ratio 100:00 00:100 80:20 90:10

As shown in table 2 the ratios of FRB was kept initially 1 and 2 kg. Whereas ERB 12065 (L) kept null and in
other experiment it was 1 kg. FRB/ERB12065 ratio was 100:00 and 50:50. Loss in the weight of the soles was
observed. The cracks also observed in the soles.

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Table 2 FRB/ERB ratio

EVA COMPOUND TRAIL (B)

Compound Code: FRB

ARTICALE:- Judger Neel size- 190

mm
SIZE-: 08 Cavity size 197
- mm

S.NO TRIAL Standard A B C D

1 BARREL 82 TO 85 85 85
TEMPERATURE 0C
2 MOLD TEMPERATURE 174 - 175 175 175
0
C
3 INJECTION PRESSURE 80 TO 82 82 82
(BAR)
4 INJECTION SPEED 22 22 22

5 DURATION TIME (sec.) 12 TO 16 SEC 26 26

6 CURING TIME (sec.) 330 TO 350 SEC 360 360

7 OPENING LENGTH mm 0 0

8 ACTUAL LENGTH mm 0 0

9 SHRINKAGE IN mm 0 0

10 REQUIRED LENGTH 280 ~ 282 280 ~ 282 280 ~ 282

mm
11 STD WEIGHT gm 220 220 220

12 ACTUAL WEIGHT gm 0 0

13 WEIGHT LOSS gm 220 220 0 0

14 Specific Observations Appearance Cracks Cracks

15 Length Afrer 16 NA NA
Hrs
16 Hardness After 16 NA NA
Hrs

Sample A B
Description
FRB- Kg 2.000 1.000

ERB- 12065 (L) 0.000 1.000

Kg
FRB / ERB-12065 100:00 50:50
Ratio

In this set of experiment the ratio of EK-02/ERB 12065 was 100:00 and 10:90. After 2 hours of curing the loss
in the weight was 53 and 25 g. While the weight after 16 h of curing was dissatisfactory and hence not
disclosed. The soles resulted were hard and small. [Chi, Cheng-Hsian, et al. (2000)], [Wun Bin, Yung et al.
(1996)] In table 3 EK-02 / ERB 12065 Ratio was kept as 100:00 10:90, as a result the sole was hard and small.
The hardness of the sole was 53 Shore A and in other experiment the soles was found to be with the hardness of
23 Shore A and was very soft. Length after 16 h could not be measured.

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Table 3 EK-02 and ERB 12065 ratio

EVA COMPOUND TRAIL (C)

Compound Code: EK-02 & ERB 12065 (L )

ARTICALE:- Judger Neel size- 190 mm

SIZE-: 08 Cavity size - 197 mm

S.NO Trials Std. A B C D

1 BARREL TEMPERATURE 0C 82 TO 85 85 85 85 85

2 MOLD TEMPERATURE 0C 174 - 175 175 175

3 INJECTION PRESSURE (BAR) 80 TO 82 82 82

4 INJECTION SPEED 22 22 22

5 DURATION TIME (sec.) 12 TO 16 Sec 26 26

6 CURING TIME (sec.) 330 TO 350 Sec 360 360

7 OPENING LENGTH mm 245 315

8 ACTUAL LENGTH mm 225 285

9 SHRINKAGE IN mm 20 30

10 REQUIRED LENGTH mm 280 ~ 282 280 ~ 282 280 ~ 282

11 STD WEIGHT gm 220 220 220

12 ACTUAL WEIGHT gm 190 198

13 WEIGHT LOSS gm 30 22

14 Specific Observations Appearance Hard & Small in Size Very Soft

15 Length After 16 Hrs - -

16 Hardness After 02 Hrs 53 25

Sample Description A B C D

EK-02 Kg 2.500 0.300 - -

ERB- 12065 (L) Kg 0.000 2.700 - -

EK-02 / ERB 12065 Ratio 100:00 10:90 - -

Table 4 displays the quality evaluations of the EVA soles. In the 1st and 2nd trials the soles were found one size
over than the standard size. But the trails 3rd and 4th yielded the soles with correct length of curing time of 360
seconds. The wrinkles problem was quite persistent throughout the experimentations. Table 4 and 5 contain the
data of the process molding with the standard norms and obtained results with the process conditions. Three
trails were carried out and the comparison may be observed from the results obtained.

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Table 4 Quality evaluation of EVA soles (ERB 12065)

S. Trials Standard 1st 2nd 3rd 4th

No.
1 Barrel Temperature 82 - 85 85-85-85-85 85-85-85-85 85-85-85-85 85-85-85-85
2 Mold Temperature 174 - 175 184-185 184-185 184-185 184-185
3 Injection Pressure 80 - 82 82-82-82-82 82-82-82-82 82-82-82-82 82-82-82-82
4 Injection Speed 22 22 22 22 22
5 Duration Time 12 - 16 Sec 10 sec 10 sec 8 sec 8 sec
6 Curing Time 330 - 350 360 sec 360 sec 360 sec 360 sec
Sec
7 Expander Mix Qty. NO NO NO NO NO
8 Reducer Mix Qty. NO NO 0.500 g 1 Kg 0.350 g
9 Actual Length 282 mm 279 mm 272 mm 281 mm
10 Opening Length 290 330 mm 325 mm 312 mm 330 mm
11 Shrinkage (mm) 18 mm 50 mm 46 mm 40 mm 49 mm
12 Required Length 272 272 mm 272 mm 272 mm 272 mm
13 Std Weight 325 325 g 325 g 325 g 325 g
14 Actual Weight 306 g 310 g 310 g 306 g
15 Results one size one size sole length sole length
over over o.k. o.k.
Problems wrinkle wrinkle wrinkle wrinkle
problem problem problem problem
weight 19 g weight 15 g weight 15 g weight 15 g
dawn dawn dawn dawn
article size: 7, NEELSIZE:185 mm
Cavity size: 197 mm

In the other study utilizing the EK-025 of 1, 0.700, and 0.500 kg resulted the soles with the shrinkage of 18, 49
and 43 mm. The opening length of the soles was 330, 320 and 300 mm, very high than the 290 mm of the
standard size. Figure 1 exhibits the functional structure of ethylene-vinyl acetate whereas the figure 2 shows the
close picture of the opened celled EVA. [Wun Bin, Yung et al (1996)], [Bisconti, Bruno, (1999)]

Table 5 Quality evaluations of EVA soles (EK-025)

S.No. Trials standard 1st 2nd 3rd

1 Barrel Temperature 82 TO 85 85-85-85-85 85-85-85-85 85-85-85-85
2 Mold Temperature 174 - 175 174-175 174-175 174-175
3 Injection Pressure 80 TO 82 82-82-82-82 82-82-82-82 82-82-82-82
4 Injection Speed 22 22 22 22
5 Duration Time 12 TO 16 Sec 16 sec 16 sec 16 sec
6 Curing Time 330 TO 350 Sec 400 sec 400 sec 400 sec
7 Expander Mix Qty. NO 1 Kg 0.700 g 0.500 g
8 Reducer Mix Qty. NO NO NO NO
9 Actual Length 281 mm 277 mm 272 mm
10 Opening Length 290 330 mm 320 mm 300 mm
11 Shrinkage (mm) 18 mm 49 mm 43 mm -

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Article sizee: 7, NEELSIZE: 185 mm

Cavity sizee: 197 mm

Foam is created whenn the gas bub bbles are trappped inside a chemical resin. Foam can be created th hrough an
endotherm mic (heat) or an exothermiic (mixing chhemicals) reacction. It starts as a solid and nd whichever process
p is
used, foaaming occurs that creates th he cell structuure and, ultimately, foam. In general, moost common closed
c cell
foam is m manufacturedd by the endotthermic and oopen cell by the t exothermiic process. Oppen cell foam m contains
bubbles w which are inteerconnected to o each other inn a wide web. Open cell foaam can be sofft and it will absorb
a any
liquid it ccomes in conttact with. It is perfect for m
many applicatio ons, especially
y if you requirre extreme sofftness and
there is nno contact witth a liquid env vironment. Annother example is a foam mattress.
m Howwever, it cannoot be used
for a floaatation applicaation, as once it begins to abbsorb liquid; it
i will absorb too much weiight in liquid and begin
to sink.

Figure 1 Ethylenne vinyl acetate

Figure 2 Close ppicture of open celled EVA

4, Discusssion

Since thee preliminary Mold 30 and the high-temp mperature Mold d 40 have sub
bstantially thee same internaal volume,
and sincee the Mold caavity 31 is deeeper and narroower than the Mold cavity 41, the blankk produced by the Mold
30 can bee placed conveniently into thet Mold caviity 41 and fill every corner in the molding ng cavity 41, and
a air can
be ventedd effectively from the Molld cavity 41, thereby avoid ding occurrence of undesiraable oxidation n reaction
with air aand deformatiion. Moreoverr, as the blankk 10 is not sub bjected to a coooling processs after being formed in
the prelliminary Moold 30, the time and energy neeeded to curre the blank nk 10 in the high-
temperatuure.[Walter;AAmaro,etal.(20 004)],[Allen,R RDetal.(2004)]]
In addition, comparedd to the conv ventional proccess in which h a foamed so ole is coloredd entirely by adding a
coloring agent to the foam
f able EVVA molding coomposition to o form the solle, the use of the thin colorred facing
sheet layer to impart a color to the outer
o surface oof the blank 10
0 only reducess the amount oof the coloringg material
needed, ssaves the costt of the colorinng material, aand decreases pollution. Besides, the timme required forr injection
molding the blank 100 is reduced as a the EVA ffoam able mo olding compo osition thereoff does not reequire any
coloring agent and thhus eliminatess the need too clean the equipment
e forr compressionn molding wh henever a
differentlly colored solle blank is dessired to be forrmed, and thee need of re-addjusting the tiime of the opening and

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closing operations to accommodate the foam able molding. While the present invention has been described in
connection with what is considered the most practical and preferred embodiment, it is understood that this
invention is not limited to the disclosed embodiment but is intended to cover various arrangements included
within the spirit and scope of the broadest interpretation so as to encompass all such modifications and
equivalent arrangements. [Allen, RD et al. (2004)]
The effect of cross linking consists in increasing the viscosity and strength of the compound during foaming so
as to settle the gas resulting from the decomposition in uniform and fine cells. Thus, concentration of the cross
linking agent added becomes important. When it is too low, the cross linking would be insufficient, resulting in
unstable cells and lack of uniformity in the foam. If the concentration is too high, excessive cross linking may
restrict foam expansion, leading to higher density foams, and also may prevent the decomposed gas from
settling in uniform and fine cells, leading to abnormal foaming. [Allen, RD et al. (2004)]
Foaming can be carried out in a compression Mold at a temperature and time to complete the decomposition of
peroxides and expanding and reducing agents. Pressures, molding temperature, and heating time are important
operation variables. Or foaming may be carried out in an injection molding equipment by using foam
compounds in pellet form. The resulting foam can be further shaped to the dimension of finished products by
any means known in the literature such as by thermoforming and compression molding. [Allen, RD et al.
(2004)]
In our finding we have revealed that fixing of the ratio of EK-025, ERB 12065 and FRB as the ratio decide the
cross linking of EVA containing a celled network. If this occurs then the soles produced may not be hard and
cracked. The size of the soles also would be expectedly as required after curing.
It was concluded the when foam density decreases, less material is available to sustain foam properties.
Therefore, it is expected that foam properties deteriorate as foam density decreases. Higher foaming temperature
shortens the cycle time. EK025, ERB 12065 and FRB also demonstrated good foam properties. In addition, the
foams exhibited high compression strength. The foam made at 174-175 o C/10 min. has compression strength of
310 kPa (approx. 45 psi) at 50% compression strain. Soles containing expanding and reducing agents also
showed high compression strength. While not bound by any particular theory or explanation, one possible
explanation is that the presence of acid copolymers, such as E/AA or related terpolymers, introduces a physical
crosslinking, in addition to the chemical cross linking caused by peroxide, for enhancing the melt strength of
foam compounds during foaming. Also, the enhanced melt strength, originated from physical cross linking not
from chemical cross linking, enables the blend foams to attain lower density and excellent foam properties.
The barrel temperature of 82-85oC, Mold temperature 174-175oC, injection pressure 80-82 bar, injection speed
22 rpm, and duration time 12-16 seconds and curing time of 330-360 seconds was the optimized process
compression conditions. [Allen, RD et al. (2004)]

Acknowledgement
Quality control department deserves special thanks for their honest endeavors in analyzing the various
parameters that were quite important for process optimization.

Nomenclature
EVA Ethylene-vinyl acetate
ERB12065 Trade name of cross linker
FRB Trade name of cross linker
EK-025 Trade name of cross linker
DOE Design of Experiments

References
[1] Cassagnau; PM, Verney BV, Michel A, (1993) Co-crosslinking of ethylene vinyl acetate and ethylene acrylic ester copolymers by
transesterification: chemical and rheological studies of kinetics, Polymer, 34 (1), pp124–131.
[2] Bambara, JD, Glydon JA (1994) Method of preparing a cross-linked, polyethylene foam product by surface expansion of a foam. US
Patent 5350544
[3] Yang, EVA insole manufacturing process. US Patent 5318645, 1994.
[4] Yang, EVA insole manufacturing process. US Patent 5308420, 1994.
[5] Yang, EVA insole manufacturing process. US Patent 5141578, 2002.
[6] Yung, Wun-bin; (Tao-Yuan, TW), Wu, Jen-hon (Nan-Tou, TW), Chang, Chung-pin (Taichung, TW), Chung, Yao-pi, (Taichung
Hsien, TW), (1996) Process for manufacturing an ethylene vinyl acetate sole using first and second Mold units. United States Patent
5560877
[7] Chi, Cheng-Hsian, Method for making an integral foamed insole with a sole body. EP 1 036 647 A1, 2000.
[8] Wun Bin, Yung; Jen Hon, Wu; Chung Pin, Chang; Yao Pi, Chung Process for manufacturing an ethylene vinyl acetate sole using first
and second mold units. United States Patent 5560877, 1996.
[9] Bisconti, Bruno, Injection Molding process for soles in expansible and cross-linking "Eva" b. United States Patent 5868981, 1999.

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[10] Walter; Amaro; Luca, Diviani; Davide, Montorfano; Ermanno, Oberrauch; Gabriele, Depinto; Simona, Segalini;Marinella,Levi,;
Stefano, Turri, (2004) Controlling the shrinkage of polymers for customized shoe sole manufacturing, International Journal of
Computer Integrated Manufacturing, 17(7), pp 633-644.
[11] Allen, RD, Newman, ST, Mitchell SR., Temple RI, Jones CL, Boer CR., Dulio S (2005) Design of experiments for the qualification of
EVA expansion characteristics, Robotics and Computer-Integrated Manufacturing, 21(4–5) pp 412–420.

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