3D printing insole with gradually connected arch partition structures and design and manufacturing method

Abstract

The application relates to a 3D printing insole with gradually connected arch partition structures and a design and manufacturing method, which comprises an arch area, adopts a first three-dimensional grid structure, an arch lateral area, adopts a multi-cubic structure, a gradual change area, which is an overlapping area of the arch area and the arch lateral area, in the area, a thickness gradually changing structure is adopted, the thickness of the first three-dimensional grid gradually decreases to the second three-dimensional grid, the thickness of the second three-dimensional grid gradually decreases to the thickness of the first three-dimensional grid, and in the gradual change area, the side with thinner thickness of the second three-dimensional grid is covered on the first three-dimensional grid. The application changes the conventional different structure block setting into different structure superposition setting, the superposition part is overlapped in the two adjacent material thickness gradually changing mode, the comfort of the foot sole, and the durability of the insole are guaranteed. Compared with the simple area directly measured, the assembly mode guarantees the accuracy of the positioning of the gradual change area.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of 3D printing orthopedic insole, in particular to a 3D printed insole with gradually connected arch partition structure and a design and manufacturing method. BACKGROUND

[0002] At present, there are insole with partition on the market, including a bottom layer for foot therapy of the foot sole, the bottom layer including arch area, toe area, front foot sole area, middle foot sole area and heel area, the five areas being filled with five different three-dimensional mesh structures.

[0003] However, the deformation degree of each part of such a partition structure insole is different, especially at the arch, after wearing for a certain period of time, the interface at the connection of different structures is not easy to deform due to the obvious interface, thereby easily leading to pain of the arch of the wearer of the insole and causing discomfort. SUMMARY

[0004] In view of the above-mentioned shortcomings in the prior production technology, the present application provides a 3D printed insole with gradually connected arch partition structure and a design and manufacturing method, which optimizes the structure of the connection of each area on the basis of the 3D printed insole with partition structure, thereby balancing the stress of the three-dimensional mesh structure of different areas, and improving the comfort and durability of the insole.

[0005] The technical solution adopted by the present application is as follows:

[0006] A 3D printed insole with gradually connected arch partition structure, comprising:

[0007] an arch area adopting a first three-dimensional mesh structure,

[0008] an outer arch area adopting a multi-cube structure,

[0009] a gradual change area being an overlapping area of the arch area and the outer arch area, in which a thickness gradually changing structure is adopted, the thickness of the first three-dimensional mesh gradually decreasing towards the second three-dimensional mesh, and the thickness of the second three-dimensional mesh gradually decreasing towards the thickness of the first three-dimensional mesh; and in the gradual change area, the side with thinner thickness of the second three-dimensional mesh is covered on the first three-dimensional mesh.

[0010] As a further improvement of the above technical solution:

[0011] The unit cell of the first three-dimensional mesh structure adopts a Dode mesh structure of Magics software.

[0012] The first three-dimensional mesh structure is subjected to the same stress in three-axis direction, the unit cell cavity is a regular tetrahedron structure, and 8 crossing nodes are arranged at the center of the unit cell connection.

[0013] The unit cell of the second stereoscopic grid structure adopts a Rhombi grid structure of Magics software.

[0014] The cavity of the second stereoscopic grid unit cell is a hexecontahedron.

[0015] A design and manufacturing method of the 3D-printed shoe pad with gradually connected arch partition structures according to claim 1, comprising the following steps:

[0016] An overall shoe pad model is scanned, taper cutting is performed in SolidWorks software, an arch part model with a taper is cut, a lateral arch region is calculated by Boolean operation, the arch region and the lateral arch region are assembled, and the vertical projection overlapping region of the two regions is obtained, which is designed as a gradual change region.

[0017] As a further improvement of the above technical solution:

[0018] The specific steps of scanning and cutting the model are as follows:

[0019] An STL file of the overall shoe pad model is obtained through digital design according to the characteristics of the patient's foot;

[0020] A circular region is marked on the shoe sole plane, a reference surface parallel to the shoe sole plane is selected at the expected height above the highest arch, and a circular region is marked on the reference surface, and the size of the circular region on the reference surface can be adjusted;

[0021] Two circles are selected as the contour for lofting operation to obtain a tapered cylindrical part,

[0022] The STL file is exported and imported into Material Magic software, the tapered cylindrical part generated by lofting is subjected to Boolean operation with the shoe pad main body, and the intersection of the two parts is the arch region;

[0023] The shoe pad main body is selected as the main body, and the above-mentioned cylindrical part is selected as the part to be subtracted, and the lateral arch region is obtained by Boolean operation; the gradual change region formed by covering the area from the shoe sole region to the upper lateral region is formed;

[0024] Select the corresponding structure units of each part of the foot sole in the toolbar software mechanics structure library, the first stereoscopic grid structure is adopted in the lateral arch region, and the second stereoscopic grid structure is adopted in the arch region.

[0025] The product is obtained by importing the slicing software and printing.

[0026] The hardness of the bottom surface of the gradual change region is greater than that of the top surface.

[0027] The beneficial effects of the present application are as follows:

[0028] The present application is directed to the possible boundary deformation of the partitioned insole, the different structure blocks are set to different structure superposition, the superposition is overlapped by two adjacent material thickness gradient, and the position of the overlapped gradient region is obtained by scanning and operation, which ensures that this region is the accurate position of the boundary of different stress positions of the foot, when the foot is pressed, the harder part in the gradient region provides support, the softer part provides comfortable foot feeling, and the long-term stress is not easy to split, even if there is a slight displacement, since the upper structure and the lower structure are inclined to each other, there will be no large gap between them, so as to ensure the comfort of the foot and the durability of the insole.

[0029] In the partition structure in the application, the foot arch outer side region corresponding to the foot part adopts a multi-cuboid structure, and the three-dimensional reticular structure formed by splicing adjacent surfaces has a large pore, which can bear a large body weight and has a reset ability when the sole is pressed from the outside, and the external force is easy to be transmitted along the multiple side walls of the polyhedron tending to a sphere. Under this premise, the hollow structure is light in weight and high in air permeability, and is suitable for force bearing of the foot arch outer side region.

[0030] The foot arch region is raised in the application, which is used to support the concave position of the foot arch, and the corresponding grid structure has the same stress in three axial directions, the cell cavity adopts a regular tetrahedron structure, and eight intersecting nodes are filled in the regular tetrahedron structure. Compared with other hollow structures, the grid density is enhanced, and the strength is enhanced. Because the regular tetrahedron is relatively easy to deform, but the material in the application is easy to reset, so it has supporting force and elasticity, and is suitable for supporting the foot arch region.

[0031] In the thickness gradient design process of the insole of the application, the region is designed in a region-by-region manner, the foot arch region is obtained first, then the outer side region of the foot arch is obtained, and the two are assembled to obtain the gradient region at the overlapping position. Compared with the simple region obtained by direct measurement, the assembly method ensures the accuracy of the positioning of the gradient region. BRIEF DESCRIPTION OF DRAWINGS

[0032] Figure 1 It is a schematic diagram of the overall structure of the insole of the application, which shows the positions of the foot arch region, the outer side region of the foot arch and the gradient region.

[0033] Figure 2 It is a sectional view of the insole of the application.

[0034] Figure 3 It is a schematic diagram of the first three-dimensional grid structure of the application.

[0035] Figure 4 It is a schematic diagram of the second three-dimensional grid structure of the application.

[0036] Figure 5A design and manufacturing flowchart of the present application.

[0037] 1, a gradual change area; 2, an outer arch area; 3, an arch area;

[0038] 21, a first stereoscopic grid structure; 31, a second stereoscopic grid structure;

[0039] 211, a first stereoscopic grid frame; 212, a first stereoscopic grid cavity; 311, a second stereoscopic grid frame; 312, a second stereoscopic grid cavity. DETAILED DESCRIPTION

[0040] The specific embodiments of the present application will be described below in conjunction with the accompanying drawings.

[0041] As shown in the drawings, the 3D printed insole with gradually connected arch partition structure of the present embodiment comprises: Figures 1-5

[0042] The arch area 3 adopts the first stereoscopic grid structure 21,

[0043] The outer arch area 2 adopts a multi-cubic structure,

[0044] The gradual change area 1 is an overlapping area of the arch area 3 and the outer arch area 2, in which a thickness gradually changing structure is adopted, the thickness of the first stereoscopic grid gradually decreases towards the second stereoscopic grid, and the thickness of the second stereoscopic grid gradually decreases towards the thickness of the first stereoscopic grid; and in the gradual change area 1, the side with thinner thickness of the second stereoscopic grid is covered on the first stereoscopic grid.

[0045] The unit cell of the first stereoscopic grid structure 21 adopts the Dode grid structure of the Magics software.

[0046] The first stereoscopic grid structure has the same stress in three-axis direction, the unit cell cavity is a regular tetrahedron structure, and eight crossing nodes are arranged at the center of the unit cell connection.

[0047] The unit cell of the second stereoscopic grid structure 31 adopts the Rhombi grid structure of the Magics software.

[0048] The cavity of the second stereoscopic grid unit cell is a hexecontahedron.

[0049] The design and manufacturing method of the 3D printed insole with gradually connected arch partition structure of claim 1 of the present embodiment comprises the following steps:

[0050] ​The whole insole model is scanned, taper cutting is carried out in the SolidWorks software, the arch part model with conicity is cut, the lateral arch area 2 is calculated by Boolean, the arch area 3 is assembled with the lateral arch area 2, and the vertical projection overlapping area of the arch area 3, the lateral arch area 2 and the two areas is obtained at this time, and the vertical projection overlapping area is designed as the gradual change area 1.

[0051] The specific steps of scanning and cutting the model are as follows:

[0052] The STL file of the whole insole model is obtained by digital design according to the characteristics of the patient's foot;

[0053] A circular area is demarcated on the sole plane, a reference surface parallel to the sole plane is selected at the expected height above the highest arch, and a circular area is demarcated on the reference surface, and the size of the circular area on the reference surface can be adjusted;

[0054] Two circles are selected as the contour to carry out lofting operation, and a conical cylindrical part is obtained,

[0055] The STL file is exported and imported into the Material Magic software, the conical cylindrical part generated by lofting is subjected to Boolean operation with the insole main body, and the intersection of the two parts is obtained as the arch area 3;

[0056] The insole main body is selected as the main body, and the above-mentioned cylindrical part is selected as the part to be reduced, and the Boolean operation is carried out to obtain the lateral arch area 2; the formed area covering from the sole area to the upper lateral area is the gradual change area 1;

[0057] The corresponding structure units of each part of the foot sole are selected from the toolbar software mechanics structure library, the first three-dimensional grid structure 21 is adopted in the lateral arch area 2, and the second three-dimensional grid structure 31 is adopted in the arch area 3;

[0058] The slice software is imported to print the finished product.

[0059] The hardness of the bottom surface of the gradual change area 1 is greater than that of the top surface.

[0060] The specific structure and design method of the application are as follows:

[0061] The insole shape is as shown in the figure, Figure 1 The insole shape is as shown in the figure,

[0062] The gradual change area 1 is an arc-shaped area between the arch area 3 and the lateral arch area 2. The structure of the gradual change area 1 is formed by overlapping structures with different hardnesses on both sides, as shown in the figure, Figure 2As shown, at the overlapping position, the first three-dimensional grid structure 21 is overlapped on the second three-dimensional grid structure 31, and the contact surfaces of the first three-dimensional grid structure 21 and the second three-dimensional grid structure 31 are inclined surfaces, respectively extending upward from the bottom surface of the first three-dimensional grid structure 21 and downward from the top surface of the second three-dimensional grid structure 31.

[0063] As shown in the drawings, the first three-dimensional grid structure 21 is a local schematic view. Figure 3 As shown in the drawings, the first three-dimensional grid structure 21 is a local schematic view.

[0064] As shown in the drawings, the second three-dimensional grid structure 31 is a local schematic view. Figure 4 As shown in the drawings, the second three-dimensional grid structure 31 is a local schematic view.

[0065] In the above two different structures corresponding to the arch and the lateral arch have been designed, the connection reliability of the two structures when used on the same insole needs to be considered.

[0066] Since the inclined surface splicing in the application is the splicing of two different materials, if the splicing area is too small, the connection area of the two different materials is small, and under the premise of receiving the same size external force, dislocation or cracking is more likely to occur; in the application, the splicing surface is adjusted to the size of the entire gradual change region 1, which can maximize the connection strength of the splicing surface and improve the stress stability.

[0067] In the application, the three-dimensional modeling of the arch and the lateral arch region is adopted, and the two three-dimensional structures are combined in an overlapping manner, the inclined surface splicing is adopted at the splicing position, and the conventional adjacent block splicing method on the same horizontal plane is replaced. The splicing area in the application has no obvious gap, and the interface between the sub-regional structures is not hard after a period of use, and the deformation degree of the two sides is inconsistent. In the application, the structure of the connection is optimized by shape, the reasonable gradual change of the different regional structures is achieved, and the disadvantages of the traditional sub-regional structure 3D printing orthopedic insole, such as hard connection between different regional structures, are solved, so that the durability and comfort of the insole are effectively improved.

[0068] The above description is an explanation of the present application, not a limitation of the present application, the scope of the present application is defined in the claims, within the protection scope of the present application, any form of modification can be made.

Claims

1. A 3D-printed insole with a gradually connected arch support structure, characterized in that: include: The arch area (3) adopts a first three-dimensional mesh structure (21). The lateral arch region (2) adopts a multi-cubic structure. The gradient region (1) is the overlapping area of ​​the arch region (3) and the outer arch region (2). In this region, a thickness gradient structure is adopted. The thickness of the first three-dimensional mesh gradually decreases towards the second three-dimensional mesh, and the thickness of the second three-dimensional mesh gradually decreases towards the thickness of the first three-dimensional mesh. In the gradient region (1), the side of the second three-dimensional mesh with a thinner thickness covers the first three-dimensional mesh.

2. The 3D-printed insole with a gradually connected arch support structure as described in claim 1, characterized in that: The unit cell of the first three-dimensional mesh structure (21) adopts the Dode mesh structure of Magics software.

3. The 3D-printed insole with a gradually connected arch support structure as described in claim 2, characterized in that: The first three-dimensional mesh is subjected to the same force in all three directions, the cell cavity is a regular tetrahedral structure, and 8 intersecting nodes are set at the center of the cell connection.

4. The 3D-printed insole with a gradually connected arch support structure as described in claim 1, characterized in that: The unit cell of the second three-dimensional grid structure (31) adopts the Rhombi grid structure of Magics software.

5. The 3D-printed insole with a gradually connected arch support structure as described in claim 4, characterized in that: The cavity of the second three-dimensional grid cell is icosahedral.

6. A method for designing and manufacturing a 3D-printed insole with a gradually connected arch support structure as described in claim 1, characterized in that, Includes the following steps: The overall insole model is obtained by scanning. Taper cutting is performed in SolidWorks software to obtain a model of the arch part with a cone. Boolean calculation is performed to obtain the outer arch region (2). The arch region (3) is assembled with the outer arch region (2). At this time, the vertical projection overlap region of the arch region (3), the outer arch region (2) and the two regions mentioned above is obtained. The vertical projection overlap region is designed as the gradient region (1).

7. The design and manufacturing method of the 3D printed insole with a gradually connected arch section structure as described in claim 6, characterized in that: The specific steps for scanning and cutting the model are as follows: Based on the patient's foot characteristics, an STL file of the overall insole model was obtained through digital design. Draw a circular area on the sole plane. Select a reference plane parallel to the sole plane at the expected height above the highest point of the arch. Draw a circular area on the reference plane. The size of the circular area on the reference plane can be adjusted. By selecting two circles as the outline and performing a lofting operation, a tapered, cylindrical-like part is obtained. Export the STL file and import it into Material Magic software. Perform Boolean operation on the tapered cylindrical body generated by the loft and the insole body. Take the intersection of the two parts to obtain the arch area (3). Select the insole body as the main body, select the above-mentioned cylindrical type as the part to be subtracted, and perform Boolean operation to obtain the outer arch area (2); the resulting area including the area covered from the sole area to the upper outer area is a gradient area (1); Select the corresponding structural units for each part of the foot from the software mechanical structure library in the toolbar. The first three-dimensional mesh structure (21) is used inside the outer arch area (2), and the second three-dimensional mesh structure (31) is used inside the arch area (3). Import the slicing software and print the finished product.

8. The design and manufacturing method of the 3D printed insole with a gradually connected arch section structure as described in claim 6, characterized in that: The bottom surface of the gradient region (1) has a harder surface than its top surface.

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