Foot bed and leather integrated forming structure and preparation method thereof

Abstract

The invention relates to the technical field of shoes, and discloses a foot bed and leather integrally-formed structure and a preparation method thereof, and the foot bed and leather integrally-formed structure comprises a leather surface layer, a supporting core layer and a bottom layer; a preset circumferential and middle array type printing area on the lower surface of the leather surface layer is subjected to plasma treatment, sprayed with resin and subjected to UV curing to form an anchoring layer, the supporting core layer is connected to the anchoring layer on the lower surface of the leather surface layer through a bottom layer to be integrally formed in a composite mode, and the supporting core layer is of a latticed bionic lattice structure. The flexible supporting core layer of the latticed bionic lattice structure is processed through the technologies such as 3D printing, the flexible supporting core layer and the leather are integrally formed, the shoe pad detachably matched with a shoe for use is manufactured, the shoe pad has the ventilation and drainage functions through the supporting core layer in the shoe pad, the shoe pad can be conveniently matched with ventilation holes in a shoe body for use, and the moisture problem is solved; in the process of matching with ventilation of the supporting core layer, the flexible buffering pad supports the foot sole surface, the comfort degree is high, cleaning and maintenance are convenient, and the insole can flexibly adapt to different shoes and is high in applicability.

Description

Technical Field

[0001] This invention relates to the field of footwear technology, specifically to a one-piece molded structure of footbed and leather, and also to a method for preparing the one-piece molded structure. Background Technology

[0002] Slippers are a common household item, also known in Chinese as lazy shoes or slippers without heels.

[0003] Supercritical foaming technology has been widely used in footwear materials, and this process has gradually become a "black technology" force in the footwear material field, slowly being pushed to the market. Slippers using supercritical foaming technology have become one of the high-end footwear products.

[0004] Even after foam molding, slippers still suffer from issues like a smooth footbed and poor breathability. To address these problems, 3D printing is currently used to create perforated insoles, which are then conveniently placed inside the footbed for effective drainage and ventilation, as well as low-cost replacement and maintenance. However, limitations exist in the 3D printing materials themselves, such as the highly flexible TPU material. The resulting perforated insoles have numerous pores, which can easily damage the skin under foot pressure. Furthermore, dirt that rubs off in damp environments can easily accumulate in the pores, making cleaning difficult and requiring further improvement. Summary of the Invention

[0005] The purpose of this invention is to provide a footbed and leather integrated molding structure and its preparation method, so as to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a footrest and leather integral molding structure, comprising a leather surface layer, a support core layer and a bottom layer; a composite connecting layer is provided on the lower surface of the leather surface layer, the support core layer is integrally molded by connecting the bottom layer to the anchoring layer on the lower surface of the leather surface layer, and the support core layer is provided with a breathable structure and the layer is soft.

[0007] As an optional embodiment of the footbed and leather integrated molding structure of the present invention, the top layer of the footbed is provided with a skin-friendly pad, which is a breathable leather pad or a composite pad containing a leather surface layer. The composite pad includes one of fleece, fiber cloth or pile connected to the microfiber cloth layer.

[0008] As an optional embodiment of the footbed and leather integrated molding structure of the present invention, wherein: the lower surface of the leather surface layer is pre-designed with a perimeter and a central array of printed areas, which are then plasma-treated, sprayed with resin, and UV-cured to form an anchoring layer.

[0009] As an alternative to the footrest and leather integrated molding structure of the present invention, the supporting core layer is integrally printed onto the anchoring layer on the lower surface of the leather surface through a fused deposition process.

[0010] As an optional solution to the footrest and leather integrated molding structure described in this invention, the material of the 3D printed support core layer is thermoplastic polyurethane elastomer.

[0011] As an optional embodiment of the footrest and leather integrated molding structure of the present invention, an interface bonding layer is provided between the leather surface layer and the 3D printed support core layer. The bonding layer is made of resin, with a spray thickness of 0.5-1 mm. After UV drying, it is cured to form an anchoring layer, so that the interface peel strength between the two is ≥4 N / mm.

[0012] A method for preparing a footrest and leather integrated molding structure includes the following steps: S1. Leather pretreatment: Cut the leather to the size of the footbed, grind the surface roughness to Ra3.2-Ra6.3μm, spray resin in the preset area, and then UV dry and cure to form an anchoring layer; S2. Fixture fixing: Fix the pre-treated leather onto the 3D printing platform, and calibrate the surface flatness of the skin-friendly pad by laser contour scanning; S3. Layered printing: Using thermoplastic polyurethane elastomer material, 3D support core layers are printed according to regionally differentiated parameters, and the laser power and scanning speed are dynamically adjusted, and the temperature during the printing process is monitored and adjusted in real time. S4. Bottom layer molding: Print a 0.5-1mm thick bottom layer on the lower surface of the 3D printed support core layer. After natural cooling, perform edge trimming to obtain the one-piece molded foot bed finished product.

[0013] As an optional embodiment of the preparation method described in this invention, the thermoplastic polyurethane elastomer in step 3 has a Shore hardness of A55-D65 and an elongation at break of ≥400%.

[0014] As an optional embodiment of the preparation method described in this invention, the accuracy of the laser contour scanning in step 2 is ±0.03mm, ensuring that the deviation between the printing path and the leather surface is ≤0.08mm.

[0015] As an optional embodiment of the preparation method described in this invention, in step 2, the leather is fixed on a 3D printing platform with vacuum adsorption function.

[0016] As an optional embodiment of the footbed and leather integrated molding structure described in this invention, the leather surface layer is adhesively bonded to the 3D-printed support core layer.

[0017] As an optional solution to the 3D printed footbed and leather integrated molding structure of the present invention, wherein: the leather surface layer and the injection-molded support core layer are integrally composite molded.

[0018] Preferably, the composite structure can be applied to slipper footbeds, sports shoe footbeds, and health shoe footbeds, wherein the compression resilience of the 3D printed support core layer is ≥80%, and the deformation is ≤5% after 100,000 fatigue tests.

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. The flexible support core layer with a mesh-like biomimetic structure is processed through 3D printing and other processes, and molded as one piece with leather to make a detachable insole for use with shoes. The insole has a breathable and drainage function through the internal support core layer, and can be easily used with the ventilation holes on the shoe body to improve the moisture problem. 2. The one-piece molded insole features a skin-friendly padding surface that contacts the foot, made of materials such as leather or fiber. Combined with the breathable support core layer, the flexible and cushioned padding provides high comfort and is easy to clean and maintain. In terms of overall structure, the sole structure can be flexibly adapted to different shoes, making it highly adaptable. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the unfolded structure of the insole in Embodiment 1 or Embodiment 2 of the present invention; Figure 2 This is a schematic diagram of the main structure of the anchoring layer on the leather surface in Embodiment 1 or Embodiment 2 of the present invention; Figure 3 This is a schematic diagram of the main view structure of the molded insole in Embodiment 1 or Embodiment 2 of the present invention; Figure 4 This is a schematic diagram of the front structure of the injection-molded insole support core layer in Embodiment 3 of the present invention; Figure 5 This is a schematic diagram of the reverse side structure of the injection-molded insole support core layer in Embodiment 3 of the present invention; Figure 6 This is a partial cross-sectional structural diagram of the injection-molded insole support core layer in embodiment 3 of the present invention when applied to a shoe; Figure 7 This is a schematic diagram of the front structure of the secondary MD insole in Embodiment 4 of the present invention; Figure 8 This is a schematic diagram of the reverse side structure of the secondary MD insole in Embodiment 4 of the present invention; Figure 9 This is a side view of the insole structure of the present invention when applied. Figure 10 This is a schematic diagram of the main structure of the sole used in conjunction with the insole of the present invention; Figure 11 This is a side view cross-sectional schematic diagram of the connection relationship between the insole and the shoe body of the present invention. Figure 12 This is a schematic front view cross-sectional view of the connection between the insole and the shoe body of the present invention. Figure 13 This is a top view schematic diagram of the connection between the insole and the sole of the present invention.

[0021] In the diagram: 1. Skin-friendly pad; 101. Leather surface layer; 102. Anchoring layer; 2. Supporting core layer; 201. Bottom layer. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] Example 1 Please see Figures 1-4 This embodiment 1 provides a molding route: integral molding during the 3D printing process.

[0024] A 3D-printed footbed and leather integrated structure, the composite structure including a 3D-printed footbed and a skin-friendly pad 1.

[0025] The skin-friendly pad 1 includes a leather surface layer 101 for connecting the 3D-printed footrest. The skin-friendly pad 1 can be a breathable leather pad or a composite pad containing the leather surface layer 101. The composite pad includes one of fleece, fiber cloth or pile attached to a microfiber fabric layer, and is composited on the other side of the leather surface layer 101 away from the anchoring layer to meet the usage needs of different customers.

[0026] The 3D printed footbed includes a 3D printed support core layer 2 and a bottom layer 201 that serves as the connecting surface of the 3D printed support core layer 2.

[0027] The lower surface of the leather surface layer 101 is pre-designed with peripheral and central array printing areas, which are then plasma-treated, resin-sprayed, and UV-cured to form an anchoring layer 102, which serves as a composite connection layer. The 3D-printed support core layer 2 is directly printed onto the anchoring layer 102 on the lower surface of the leather surface layer 101 using a fused deposition modeling process. The 3D-printed support core layer 2 has a mesh-like biomimetic lattice structure and is made of thermoplastic polyurethane elastomer, providing a flexible cushioning effect. It works in conjunction with the skin-friendly pad 1 to provide flexible cushioning and support for the foot.

[0028] It should be noted that: several ventilation holes are punched into the pad body outside the area of ​​the anchoring layer 102. The ventilation holes are connected to the 3D printed support core layer 2 to improve the breathability.

[0029] In this embodiment 1, in order to meet the requirements of integrated printing molding: an interface bonding layer is provided between the leather surface layer 101 and the 3D printed support core layer 2. The bonding layer is resin with a spray thickness of 0.5-1MM. After UV drying, it is cured to form an anchoring layer 102, so that the interface peel strength between the two is ≥4N / mm, so that the 3D printing molding work can proceed stably.

[0030] A method for fabricating a 3D-printed footrest and a one-piece leather structure includes the following steps: S1. Leather pretreatment: Cut the leather to the size of the footbed, grind the surface roughness to Ra3.2-Ra6.3μm, spray resin in the preset area, and then UV dry and cure to form anchoring layer 102.

[0031] S2. Fixture Fixing: Fix the pre-treated leather onto the 3D printing platform. The surface flatness of the skin-friendly pad 1 is calibrated by laser contour scanning. The accuracy of this laser contour scanning is ±0.03mm, ensuring that the deviation between the printing path and the leather surface is ≤0.08mm, with high accuracy.

[0032] The leather is fixed to a 3D printing platform with vacuum adsorption function.

[0033] It should be noted that the leather has a nap. When vacuum adsorption is used for fixation, the nap is smoothed out and the leather surface layer 101, which serves as a support pad, can still be fixed during vacuum adsorption.

[0034] S3. Layered printing: Thermoplastic polyurethane elastomer material is used with a Shore hardness of A55-D65 and an elongation at break of ≥400% to meet the elastic recovery requirements of the foot pad; 3D support core layer is printed according to regionally differentiated parameters, and the laser power and scanning speed are dynamically adjusted, and the temperature during the printing process is monitored and adjusted in real time. S4. Bottom Layer 201 Molding: A 0.5-1mm thick bottom layer 201 is printed on the lower surface of the 3D printed support core layer 2. After natural cooling, the edges are trimmed to obtain the one-piece molded foot bed finished product.

[0035] The skin-friendly pad 1 can be a breathable leather pad or a composite pad containing a leather surface layer 101. The composite pad includes one of fleece, fiber cloth or pile attached to the microfiber cloth layer, and is composited on the other side of the leather surface layer 101 away from the anchoring layer to meet the usage needs of different customers.

[0036] It should be noted that the above-mentioned one-piece molded product can be applied to slipper footbeds, sports shoe footbeds, and health shoe footbeds. The 3D printed support core layer 2 has a compression resilience rate of ≥80% and a deformation of ≤5% after 100,000 fatigue tests, demonstrating good performance.

[0037] In terms of overall structure, the product is manufactured in one piece using 3D printing technology on the leather surface 101. The process is stable, and the skin-friendly outer surface helps to improve the problem of skin damage under pressure, and cleaning and maintenance are also convenient.

[0038] Example 2 Referring to the structure of Embodiment 1, this Embodiment 2 provides another approach compared to the composite molding method in Embodiment 1: composite molding after 3D printing.

[0039] A 3D-printed footbed and leather integrated structure, the composite structure including a 3D-printed footbed and a skin-friendly pad 1.

[0040] The skin-friendly pad 1 includes a leather surface layer 101 for connecting the 3D-printed footrest. The skin-friendly pad 1 can be a breathable leather pad or a composite pad containing the leather surface layer 101. The composite pad includes one of fleece, fiber cloth or pile attached to a microfiber fabric layer, and is composited on the other side of the leather surface layer 101 away from the anchoring layer to meet the usage needs of different customers.

[0041] The 3D printed footbed includes a 3D printed support core layer 2 and a bottom layer 201 that serves as the connecting surface of the 3D printed support core layer 2.

[0042] In this embodiment 2, the lower surface of the leather surface layer 101 is pre-designed with peripheral and central array-shaped printing areas, which are then plasma-treated, sprayed with resin, and UV-cured to form an anchoring layer 102. The anchoring layer 102 serves as a composite connecting layer. The 3D-printed support core layer 2 is supported separately by a 3D printer, and the bottom surface is fitted with the anchoring layer 102 to form a bottom layer 201. The anchoring layer 102 on the leather surface layer 101 is adhesively bonded to the bottom layer 201 of the 3D-printed support core layer 2.

[0043] Among them, the 3D-printed support core layer 2 has a mesh-like biomimetic lattice structure and is made of thermoplastic polyurethane elastomer, which has a flexible cushioning effect and works with the skin-friendly pad 1 to provide flexible cushioning and support for the soles of the feet.

[0044] In Example 2, the bottom layer 201 is the bottom support connection surface when the product is cut and formed on the printing platform, which is denser than the support core layer 2 of 3D printing.

[0045] It should be noted that in various embodiments, the connection method of the composite pad includes, but is not limited to, adhesive bonding. After processing and molding, a composite velvet, fiber cloth or fleece can be additionally bonded to the outer surface of the molded product to make the outer surface of the skin-friendly pad 1 comfortably contact the sole of the foot and meet the usage needs of different customers.

[0046] Example 3 Referring to a portion of the structure in Embodiment 1 or Embodiment 2, please refer to... Figures 4-6Compared to the 3D printing molding method in Example 1 or Example 2, this Example 3 provides another route: integral injection molding foam composite molding.

[0047] A footbed and leather integrated molding structure, the composite molding structure including an injection-molded footbed and a skin-friendly pad 1.

[0048] The skin-friendly pad 1 includes a leather surface layer 101 for connecting the injection-molded footbed. The skin-friendly pad 1 can be a breathable leather pad, or a composite pad containing a leather surface layer 101 coated with a hot melt adhesive film. The composite pad includes one of fleece, fiber cloth, or pile attached to a microfiber fabric layer, and is laminated on the other side of the leather surface layer 101 coated with a hot melt adhesive film to meet the usage needs of different customers.

[0049] The injection molding footbed includes a support core layer 2 and a bottom layer 201 that serves as the connecting surface of the support core layer 2.

[0050] A hot melt adhesive film is applied to the lower surface of the leather surface layer 101 as a composite bonding layer. The skin-friendly pad 1 has several breathable holes punched into its body, which connect to the supporting core layer 2 to improve breathability.

[0051] After the breathable holes are punched on the skin-friendly pad 1, it is placed into the mold, the mold is closed and TPU or TPR material is injected, which has a flexible cushioning effect. The hot melt adhesive film layer on the lower surface of the leather surface layer 101 is combined with the bottom layer 201 of the injection-molded support core layer 2. The mold is cooled and removed to make an injection-molded composite one-piece product, which can provide flexible cushioning and support for the foot.

[0052] It should be noted that after the injection-molded support core layer 2 is formed, ventilation holes are also provided on the layer.

[0053] It should be noted that the bottom surface of the injection-molded foam composite insole, which is the bottom surface of the injection-molded support core layer 2, has a grid structure. Each ventilation hole corresponds to a grid groove on the bottom surface of the insole. The edge of each grid groove has a notch for interconnection, that is, drainage grooves for mutual ventilation are set between the ventilation holes. The groove width is 1.5-3mm and the depth is 1.5-2.5mm, which provides good breathability.

[0054] Example 4 Refer to the partial structure of Embodiment 3, and then refer to... Figures 7-8 In contrast to the one-piece injection foam composite molding in Example 3, Example 4 provides another molding structure.

[0055] A footbed and leather integrated molding structure, the composite molding structure including an injection-molded footbed and a skin-friendly pad 1.

[0056] The skin-friendly pad 1 includes a leather surface layer 101 for connecting the injection-molded footbed. The skin-friendly pad 1 can be a breathable leather pad or a composite pad containing a hot melt adhesive film composited with the leather surface layer 101. The composite pad includes one of fleece, fiber cloth or pile attached to a microfiber cloth layer, and is laminated on the other side of the hot melt adhesive film of the leather surface layer 101 to meet the usage needs of different customers.

[0057] The injection molding footbed includes a support core layer 2 and a bottom layer 201 that serves as the connecting surface of the support core layer 2.

[0058] The lower surface of the leather surface layer 101 is laminated with a hot melt adhesive film as a composite connecting layer. The skin-friendly pad 1 has several breathable holes punched into its body, which connect to the supporting core layer 2 to improve breathability.

[0059] After the breathable holes are punched on the skin-friendly pad 1, it is placed in the mold and then subjected to secondary MD composite molding. The hot melt adhesive film on the lower surface of the leather surface layer 101 is hot-pressed and bonded to the bottom layer 201 of the support core layer 2. After cooling, the pad is removed and a one-piece injection molded composite product is produced, which can provide flexible cushioning and support for the feet.

[0060] It should be noted that after the injection-molded support core layer 2 is formed, ventilation holes are also provided on the layer.

[0061] Example 5 Application instructions for the molded products in Examples 1-4: Based on Examples 1-4, please refer to the following examples: Figures 9-13 A shoe that uses a footbed and a one-piece molded leather insole, including a breathable sole.

[0062] A storage slot is made inside the footbed of the shoe sole, and the removable insole is placed in the storage slot to form a complete shoe.

[0063] The outer layer of the insole is made of leather or velvet, serving as the footbed surface that contacts the sole of the foot, thus improving comfort.

[0064] Through holes are made on both sides of the sole to connect the storage slots. The 3D printed support core layer 2 of the insole connects to each through hole for ventilation and drainage. This method can be applied to slipper footbeds, sports shoe footbeds or health shoe footbeds, and has strong applicability.

[0065] Note: The example here uses the 3D-printed support core layer 2 from Example 1.

[0066] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A footbed integrated with leather structure, characterized in that: The leather surface layer, the supporting core layer and the bottom layer are provided; the lower surface of the leather surface layer is provided with a composite connecting layer; the supporting core layer is integrally formed with the anchoring layer on the lower surface of the leather surface layer through the bottom layer; the supporting core layer is provided with a breathable structure; and the layer body is soft.

2. The footbed and leather one-piece structure according to claim 1, wherein: The top layer of the footbed is provided with a skin-friendly pad, which is a breathable leather pad or a composite pad containing a leather surface layer. The composite pad includes one of flannel, fiber cloth or down on a microfiber cloth layer.

3. The footbed and leather one-piece structure according to claim 2, wherein: The lower surface of the leather surface layer is provided with a preset circumferential and middle array type printing area, which is treated by plasma and sprayed with resin and UV cured to form an anchoring layer as a composite connecting layer.

4. The footbed and leather one-piece structure according to claim 3, wherein: The supporting core layer is integrally printed on the anchoring layer on the lower surface of the leather surface layer by a fused deposition process.

5. The footbed and leather one-piece structure according to claim 4, wherein: The material of the supporting core layer is thermoplastic polyurethane elastomer.

6. The footbed and leather one-piece structure according to claim 5, wherein: An interface bonding layer is provided between the leather surface layer and the 3D printed supporting core layer. The bonding layer is resin, with a spraying thickness of 0.5-1mm, which is cured to form an anchoring layer after UV drying, so that the interfacial peeling strength of the two is ≥4N / mm.

7. The footbed and leather one-piece structure according to claim 3, wherein: The leather surface layer is glued and combined on the 3D printed supporting core layer.

8. The footbed and leather one-piece structure of claim 2, wherein: The leather surface layer and the injection molded supporting core layer are integrally formed.

9. A method of manufacturing a footbed integrated with a leather structure according to any one of claims 1 to 6, characterized in that, The method comprises the following steps: S1. Leather pretreatment: cut the leather to the size of the footbed, polish the lower surface roughness to Ra3.2-Ra6.3μm, spray resin in the preset area, and then UV dry and cure to form an anchoring layer; S2. Tooling fixation: fix the pretreated leather on the 3D printing platform, and calibrate the surface flatness of the skin-friendly pad by laser contour scanning; S3. Layer printing: adopt thermoplastic polyurethane elastomer material, print 3D supporting core layer according to regional differentiation parameters, dynamically adjust laser power and scanning speed, and monitor and adjust temperature in real time during printing; S4. Bottom layer forming: print a 0.5-1mm thick bottom layer on the lower surface of the 3D printed supporting core layer, and perform edge trimming treatment after natural cooling to obtain an integrally formed footbed product.

10. The method of claim 9, wherein: The Shore hardness of the thermoplastic polyurethane elastomer in step 3 is A55-D65, and the elongation at break is ≥400%.

11. The method of claim 10, wherein: The accuracy of the laser contour scanning in step 2 is ±0.03mm, which ensures that the deviation of the printing path from the leather surface is ≤0.08mm.

12. The method of claim 11, wherein: In step 2, the leather is fixed on a 3D printing platform with vacuum adsorption function.

13. The unitary structure of any one of claims 1-8 or the method of making of any one of claims 10-12, wherein: The forming structure can be applied to slippers footbed, sports shoes footbed, and health care shoes footbed, wherein the compression resilience of the 3D printed supporting core layer is ≥80%, and the deformation after 100000 times fatigue test is ≤5%.

Images