The air (atmosphere) contains nitrogen and oxygen. Through high-pressure electrolysis, nitrogen and oxygen atoms are dissociated, and with the added influence of magnetic forces, high-energy ion beams are formed. These ion beams exhibit higher concentration, intensity, stability, and controllability compared to plasma.
The ionized oxygen atom will combine with the carbon atom from the material surface and form carbon dioxide molecular, meanwhile, increasing the surface area of the material which can be considered as a nanoscale of buffing. The nitrogen atom will create some functional groups with the material surfaces, which will enhance the hydrophilicity of the surfaces temporarily. A surface with strong hydrophilicity can form a robust covalent with primer for creating a strong bonding strength.
The Air Aurora is an optimized form of plasma, surpassing traditional plasma in various performance aspects, including concentration, strength, stability, controllability, and uniformity. Advanced aurora processing technologies have overcome the shortcomings of traditional plasma, serving the manufacturing industry with higher quality production and lower energy consumption/pollution.
Aurora processing can replace traditional shoe manufacturing front-end processes such as roughing, acid-base washing, and treatment agents, eliminating the large amount of dust, wastewater, and air pollution caused by the original process. Moreover, it can save energy and improve bonding quality!
Reduce Buffing dust
Reduce cementing water waste
Reduce chemical primer
Save human resources
Stable quality
Energy conservation
increase bonding strength and efficiency.
Specialize in manufacturing complicated shoes
Yield 100% – buffing evenly, Auto QC system
Save human resources
Stable quality
Energy conservation
From the comparison of two sets of groups in the graph (Group 1-2 and Group 3-4), it is clear that the shoe sole samples treated with Aurora (Nos. 2 and 3) have significantly higher maximum tensile strength than those not treated with Aurora. As evident from this chart, Aurora processing can significantly enhance bonding strength.
The camera at the front end of the Air Aurora equipment conveyor belt automatically photographs the shoe materials and immediately analyzes the size, depth, curvature, and material of the shoes. The robotic arm sprays the shoe materials using the optimal spraying path, multi-angle directions, and flexibly adjustable parameters, providing flexible and optimal solutions for complex shoe production lines.
The equipment system operates quickly and efficiently, processing one shoe in an average of 10 seconds, with an hourly output of 180 pairs. When combined with the automated QC debugging system, it effectively eliminates incompletely processed uppers, ensuring a 100% yield.
The Aurora processing equipment has been introduced into the shoe mass production line for several years, testing and mass producing hundreds of shoe soles, including various materials (RB, EVA, TPU…) and various curved shapes (flat plates, high side walls…). Its material application versatility and bonding quality have been acknowledged and certified by shoe manufacturers and consumers.
The atomic force microscope (image size: 1um*1um) reveals changes in surface roughness before and after the Aurora treatment. This nano-scale micro-roughening effect not only doubles the surface area of the material but also has no impact on the appearance of the material itself.
Air Aurora automated equipment is excellent for treating high sidewall shoe soles and other complex shaped soles, including climbing shoes, sports shoes, work shoes, etc.
Combined with a visual recognition system and a robotic arm, Air Aurora automated equipment can easily handle edges and corners that are difficult for humans to manage, swiftly and accurately.
The wide range of shoe sole materials suitable for Air Aurora has been proven on production lines. Aurora equipment has been successfully applied to mass production of various international brand shoes, accumulating over 6 years of practical experience. Whether it’s rubber soles, TPU, EVA, or other common shoe sole materials, Air Aurora shows excellent processing benefits. Its superior bonding effect has been recognized by international brands, famous OEMs, and consumers.
Air Aurora equipment has been formally introduced into the top three global footwear OEMs for over 6 years, and continues to receive repeat orders. This proves that its powerful bonding enhancement effects are applicable to various shoe types and materials. Furthermore, the bonding quality of Air Aurora technology has received wide recognition from international brands, well-known OEMs, and consumers.
In the early stages, due to a lack of understanding and experience in plasma engineering among footwear professionals, many difficulties and challenges were encountered during actual mass production, sometimes even causing doubts about being overly optimistic. However, by 2017, with the involvement of more professionals and technical teams with knowledge of materials and plasma engineering, we were able to break past limitations and truly apply atmospheric plasma technology to the footwear industry. This solved the pollution issues in traditional shoemaking, transforming the footwear industry into a fashionable and environmentally friendly industry.
Automation can’t be achieved overnight; it needs to be gradually implemented. Because it involves various factors such as whether equipment design and functions match production needs, whether equipment investment and expected returns are in line, and society’s awareness and investment attitude towards automation and environmental protection. Automation is undoubtedly a future trend, but gradually introducing automated equipment is key to successful implementation. This helps identify and solve problems more easily, and also provides more flexibility for shoe factories in terms of manpower allocation and equipment investment.
