Sole component for sports shoes, manufacturing method of sole component and sole structure with sole component

Abstract

The present invention relates to a sole part for sports shoes, comprising a toe part, a half sole part, a midfoot part and a heel part which are sequentially connected from front to back in the longitudinal direction, in which an arch part comprises a pair of side strips, and a first cross strip and a second cross strip which connect the side strips on both sides in the transverse direction. The invention also provides a metal additive manufacturing method of the sole component. The sole component enables the side edge strips to form outward expansion deformation due to downward gravity, the outward expansion deformation of the side edge strips is converted into lifting of the heel part of the sole component, and lifting of the heel part forms a passive lever through force conduction and rolling effects to form forward propelling force. The invention also relates to a sole structure with the sole component.

Description

Technical Field

[0001] The present invention relates to the field of sports shoes. Specifically, the present invention relates to a sole component and a sole assembly structure that converts gravity into propulsion, thereby enhancing propulsion during exercise. Another aspect of the present invention also relates to a method for manufacturing the sole component and a sole structure having the same. Background Art

[0002] When a person is running in shoes, they push and stretch to move forward. The soles of sports shoes are often made of softer materials such as foam materials (such as EVA or ETPU, etc.), which have the advantages of being soft, comfortable, and having good shock-absorbing effects. In order to improve the propulsion performance of shoes, the existing propulsion structures on the market are mainly some sports shoes that add propulsion plates with excellent hardness and elasticity, such as carbon fiber plates, to the soles. Most propulsion plates are one-piece structures with a certain curvature, and a few are double-layered propulsion plates. However, the existing propulsion force structures all use a single lever to achieve force transmission, and the propulsion force that can be achieved by using a single lever to achieve force transmission is always limited due to the limitations of materials, structures, and product design itself.

[0003] With the advancement of science and technology, additive manufacturing technology is changing traditional manufacturing methods. In particular, metal additive manufacturing technology, as an important part of the additive manufacturing field, has brought unprecedented flexibility and efficiency to product design and production. Metal additive manufacturing is the process of building three-dimensional objects by adding materials layer by layer. Common metal additive manufacturing technologies include selective laser melting (SLM), electron beam melting (EBM) and direct metal laser sintering (DMLS). These technologies are all based on the principle of powder bed fusion, using high-energy sources such as lasers or electron beams to melt and solidify metal powder into the desired geometry. Metal additive manufacturing has the advantages of high customization, high material utilization, the ability to shorten the R&D cycle to accelerate the launch of new products, support lightweight design, and the ability to create parts with complex cavities or channels.

[0004] Despite its numerous advantages, metal additive manufacturing (AM) faces several technical and economic challenges. First, high equipment costs limit the ability of small and medium-sized enterprises to adopt this technology. Second, material selection is limited; not all metals are suitable for existing AM processes. Furthermore, quality control and standardization are crucial; ensuring the consistency and reliability of each printed part is crucial. To overcome these challenges, researchers are continuously exploring new solutions. On the one hand, they are committed to developing more cost-effective machines and new materials, while on the other hand, they are also working to improve quality inspection methods and technical specifications. As the technology matures, the cost of metal AM will continue to decline, and market acceptance will increase accordingly. At the same time, emerging technologies such as artificial intelligence and the Internet of Things will inject new vitality into metal AM, reaching new heights in intelligent manufacturing.

[0005] The propulsion force that can be achieved by existing sports shoe sole propulsion components is limited due to limitations in materials, structure, and product design. New materials and new designs are still needed in the development of sole structure propulsion components. Summary of the Invention

[0006] Therefore, an object of the present invention is to provide a novel sole component by combining metal additive manufacturing technology to achieve a breakthrough in improving the propulsion force of sports shoes, as well as a sports shoe sole comprising the sole component.

[0007] Athletic shoes equipped with the sole component according to the present invention can utilize the double-lever principle to provide propulsion for running users, thereby improving their athletic performance. During exercise, downward pressure on the arch of the sole component causes the deformation elements of the first and second horizontal bars to deform laterally, generating an outward expansion force. This in turn causes the side bars to deform outward, forming an active lever. This leverages the mechanical non-reciprocity structure to lift the heel, providing propulsion. Simultaneously, after the heel is lifted, the sole component's rigidity creates a passive lever through force conduction and rolling effects, forming a fulcrum near the arch. Pressure on the forefoot causes the heel to lift, generating forward propulsion.

[0008] The sole component provided by the present invention is made by metal additive manufacturing technology. Specifically, the sole component is prepared by nickel-titanium metal powder laser sintering process. The prepared nickel-titanium alloy sole component has good rigidity and sufficient toughness at the same time. It can strike a balance between rigidity and toughness, so that the sole component can have sufficient toughness to deform the side strips to lift the heel to form an active lever when subjected to vertical downward gravity, and at the same time have sufficient rigidity to form a passive lever through the rolling effect to provide forward thrust. In addition, the nickel-titanium alloy sole component provided by the present invention can be produced to be thinner than the sole component of the prior art, while having performance that is not inferior to the sole component of the prior art, such as rigidity and toughness. The sole component produced by metal additive manufacturing technology has a high degree of design flexibility, and the three-dimensional model of the sole component can be adjusted by computer at any time, such as the drop (height and height), thickness, and local angle of the sole component.

[0009] The present invention provides a sole component for an athletic shoe, which is used within a sole structure and has a longitudinal and lateral direction perpendicular to each other, as well as a vertical direction perpendicular to the longitudinal and lateral directions. The sole component, from front to back, longitudinally comprises a toe portion corresponding to the shape of the toe area of the sole of the foot, a forefoot portion connected to the toe portion and corresponding to the metatarsophalangeal joint area of the sole of the foot, a heel portion corresponding to the heel area of the sole of the foot, and an arch portion having a hollow area bridging the forefoot portion and the heel portion. The arch portion comprises a pair of side strips extending from two lateral sides of the rear end of the forefoot portion to two lateral sides of the front end of the heel portion; a first horizontal strip located near the forefoot portion of the sole arch portion, parallel to the lateral direction, connecting the two side strips in the lateral direction; and a second horizontal strip located near the heel portion of the sole arch portion, parallel to the lateral direction, connecting the two side strips in the lateral direction. The sole component is entirely additively manufactured from a metal material, wherein the metal material comprises one or more of a titanium alloy, a nickel alloy, a stainless steel, an aluminum alloy, and a cobalt-chromium alloy.

[0010] As a preferred aspect of the present invention, the toe portion and forefoot portion further include a boss spanning therebetween, the boss being parallel to the plane of the sole component and vertically located above the sole component, and a plurality of struts extending downward at a certain angle from the front and rear ends of both sides of the boss, the struts extending to both sides of the rear end of the toe portion and both sides of the front end of the forefoot portion to be connected to the sole component.

[0011] As a preferred aspect of the present invention, the sole component is made of nickel-titanium metal powder additive manufacturing, wherein the ratio of nickel to titanium powder is 53-56 wt.%, and 44-47 wt.% by weight.

[0012] As a preferred aspect of the present invention, the sole component is made of nickel-titanium metal powder additive manufacturing, wherein the ratio of nickel to titanium powder is 55wt.%, 45wt.% by weight.

[0013] As a preferred aspect of the present invention, the thickness of the sole component in the vertical direction ranges from 0.7 mm to 1.2 mm.

[0014] As a preferred aspect of the present invention, through holes are distributed on the upper surface, the lower surface and / or the side surfaces of the sole component, wherein any one of the shape, size and mutual spacing of the through holes is adjustable.

[0015] The present invention also provides a method for manufacturing a sole component, which comprises the following steps:

[0016] Step 1: Generate a 3D model of the sole component on a computer, and use slicing software to convert the 3D model into a series of 2D plane models perpendicular to the laser irradiation direction;

[0017] Step 2: Before printing, the nickel-titanium metal powder was vacuum dried in a vacuum oven at 80°C for 6-7 hours;

[0018] Step 3: introducing a mixed inert gas into the additive manufacturing machine as a shielding gas, wherein the mixed inert gas includes at least two inert gases, one of which is nitrogen, and the volume proportion of nitrogen is 20%-75%;

[0019] Step 4: Metal powder is spread or applied on the powder bed by a roller or scraper. The laser scans and melts the powder according to the slicing pattern, thereby selectively building horizontal metal thin layers one by one.

[0020] Step 5: The powder bed is lowered one level and the above process is repeated until the sole component is completely built.

[0021] Step 6: post-treating the obtained sole component by keeping it at a temperature range of 450° C. to 550° C. for 2 to 4 hours.

[0022] As a preferred aspect of the present invention, in step 1, the distance between the layered slices is between 0.03 mm and 0.04 mm.

[0023] As a preferred aspect of the present invention, during the laser scanning process, the forming parameters include laser power in the range of 200W-250W, laser scanning speed in the range of 500-600mm / s and scanning spacing in the range of 0.10mm-0.15mm.

[0024] The present invention also provides a sole structure, which includes an upper midsole and a lower midsole that are cooperatively connected to each other, a sole component built between the upper midsole and the lower midsole, and a shoe outsole, wherein the sole component is the above-mentioned sole component for sports shoes and either the upper midsole or the lower midsole is provided with a groove for accommodating the sole component, wherein the shape of the groove is designed to be consistent with the contour of the sole component. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings, in which:

[0026] Figure 1 shows a top view of an embodiment of a sole component according to the present invention;

[0027] Figure 2 shows a top view of an embodiment of a sole component according to the present invention;

[0028] Figure 3 shows a top view of an embodiment of a sole component according to the present invention;

[0029] Figure 4 A top view showing another embodiment of a sole component according to the present invention;

[0030] Figure 5 A top view showing another embodiment of a sole component according to the present invention;

[0031] Figure 6 shows side views of three different embodiments of a sole component according to the present invention;

[0032] Figure 7 shows a perspective view of another embodiment of a sole component according to the present invention;

[0033] Figure 8 A flow chart showing a method for manufacturing a sole component according to the present invention;

[0034] Figure 9 A bottom view of the upper midsole of the sports shoe sole according to the present invention is shown;

[0035] Figure 10 An exploded view of a sports shoe sole according to the present invention is shown.

[0036] Description of Reference Numerals

[0037] 100-sole component; 110-toe portion; 120-forefoot portion; 130-arch portion; 140-heel portion; 111-first groove; 112-first through hole; 121-second groove; 122-third groove; 131-first side strip; 132-second side strip; 133-second through hole; 134-first horizontal strip; 135-second horizontal strip; 136-first deformation unit; 137-second deformation unit; 138-third deformation unit; 139-fourth deformation unit; 141-third through hole; 151-boss; 152-pillar; 201-upper midsole; 202-lower midsole. DETAILED DESCRIPTION

[0038] The sole component 100 and the sports shoe sole including the same of the present invention will be further described in detail below in conjunction with specific embodiments. The given embodiments are only for illustrating the present invention, and are not intended to limit the scope of the present invention.

[0039] In this document, the terms "first deformation element," "second deformation element," "third deformation element," and "fifth deformation element" are used solely to distinguish deformation elements located at different locations. This terminology does not necessarily imply that these deformation elements have identical or different structures. An embodiment having a fourth deformation element (as described below) does not necessarily mean that a second and / or third deformation element must also be present. This disclosure fully encompasses embodiments that, for example, have a first deformation element and a fourth deformation element, but, for example, do not have a second deformation element.

[0040] In this article, the concept of the term "sports shoes" can be applied to a wide range of shoes suitable for various daily or sports occasions, including but not limited to: walking shoes, running shoes, casual shoes, tennis shoes, soccer shoes, American football shoes, basketball shoes, cross-training shoes, spike shoes, golf shoes, etc.

[0041] The term "longitudinal" refers to the direction in which a component extends. For example, the longitudinal direction of an athletic shoe extends between the forefoot region and the heel region of the athletic shoe. The terms "forward" or "forward direction" are used to refer generally to the direction from the heel region toward the forefoot region, and the terms "rearward" or "rearward direction" are used to refer to the opposite direction, that is, from the forefoot region toward the heel region. In some cases, a component may be identified by a longitudinal axis and the forward and rearward longitudinal directions along that axis. The longitudinal direction or axis may also be referred to as the front-rear direction or axis.

[0042] The term "lateral" refers to the direction along which a component extends. For example, the lateral direction of a sneaker runs between the lateral side and the medial side of the sneaker. The lateral direction or axis may also be referred to as the lateral direction or axis or the mediolateral direction or axis.

[0043] The terms "vertical" or "upright" refer to a direction that is generally perpendicular to both the lateral and longitudinal directions. For example, where the sole structure rests flat on a ground surface, the vertical direction may extend upward from the ground surface. It will be understood that each of these directional adjectives above may apply to individual components of the sole structure. The terms "upward" or "upwardly" refer to a vertical direction directed toward the top of a component. The terms "downward" or "downwardly" refer to a vertical direction opposite to the upward direction, directed toward the bottom of a component, and may generally be directed toward the bottom of the sole structure of the athletic shoe.

[0044] At the same time, for consistency and convenience, directional adjectives may be used throughout this detailed description corresponding to the illustrated embodiments. Those skilled in the art will recognize that terms such as "above," "below," "upward," "downward," "top," "bottom," and the like may be used descriptively with respect to the accompanying drawings and do not represent limitations on the scope of the invention as defined by the claims. The term "horizontal" refers to a plane extending in the longitudinal and transverse directions and perpendicular to the vertical direction.

[0045] Unless otherwise expressly or clearly indicated in light of the context, all numerical values for parameters (e.g., amounts or conditions) in this specification and claims should be understood as being modified in all instances by the term "about" or "approximately," regardless of whether "about" or "approximately" actually appears before the numerical value. "About" indicates that the numerical value described allows for some slight imprecision (close to the exact value to a certain extent; approximately or reasonably close to the value; almost). If the imprecision provided by "about" or "approximately" is not understood in this ordinary sense in the art, then "about" or "approximately" as used herein at least indicates the variation that may result from ordinary methods of measuring and using these parameters.

[0046] Sole components

[0047] refer to Figure 1 and Figure 2, shows a top view of an embodiment of a sole component 100. From a top-down perspective, the overall shape of the sole component 100 is similar to the projected shape of the sole of the foot. The sole component 100 includes a toe portion 110, a forefoot portion 120, an arch portion 130, and a heel portion 140, which are connected in sequence longitudinally from left to right and from front to back. The shape of the toe portion 110 of the sole component is similar to the outline of a toe, with a first groove 111 extending longitudinally from the middle area of the front end of the toe portion 110. From a top-down perspective, the first groove 111 has rounded corners at its ends, a lateral width of 10-12 millimeters, and a longitudinal depth of 15-18 millimeters. A first, roughly semicircular, through-hole 112 is also provided in the toe portion 110 region. The diameter of the first through-hole 112 is arranged transversely, with the arc end facing the front side of the sole component 100. The diameter of the first through-hole 112 roughly accounts for 80% of the maximum width of the sole component 100.

[0048] The forefoot portion 120 corresponds to the metatarsophalangeal joint of the foot and serves as the central portion of the sole component 100, connecting the toe portion 110 and the arch portion 130. Viewed from above, the forefoot portion 120 is a rectangle with grooves on either side. Its lateral length is greater than its longitudinal length, with a ratio of approximately 3:1. Two opposing grooves, a second groove 121 and a third groove 122, are arranged on either side of the forefoot portion 120. The width of each groove gradually increases from the bottom to the top. Both the bottom and top ends of the second and third grooves 121, 122 are rounded, creating a smooth transition and reducing localized stress during manufacturing. Viewed from the side, the forefoot portion 120 arches upward in a certain arc, reaching its highest point in the middle and descending toward the toes 110 and arch portion 130 on either side.

[0049] Because the forefoot portion 120 corresponds to the metatarsophalangeal joint of the foot, the arrangement of the second groove 121 and the third groove 122 allows the forefoot portion 120 of the sole component 100 to deform in a predetermined manner as the metatarsophalangeal joint changes when a user wears the athletic shoe with the sole component 100. The toe portion 110 and the arch portion 130 can adjust relative to each other as the angle between the toes and the arch of the foot changes when the user steps, due to the bending of the forefoot portion 120. The second groove 121 and the third groove 122 facilitate the deformation of the forefoot portion 120 and ensure a better fit to the sole of the user's foot. Furthermore, the midsole of the shoe containing the sole component 100 is arranged to match the shape of the sole component 100, ensuring a tight fit between the sole component 100 and the midsole, making it less likely to cause defects such as separation and movement between the sole component 100 and the midsole. The structure of the midsole will be described in detail below.

[0050] The arch portion 130 includes two longitudinally arranged, symmetrical side strips and two transverse strips bridging the two side strips. A first side strip 131 and a second side strip 132 each connect at one end to the forefoot portion 120, respectively, and converge at the other end to connect to one end of the heel portion 140. Together with the forefoot portion 120 and the heel portion 140, the two side strips form a second through hole 133. The two side strips are connected by a transversely arranged first transverse strip 134 and a second transverse strip 135. The first transverse strip 134 is arranged approximately parallel to the transverse direction near the junction of the side strips with the forefoot portion 120. The second transverse strip 135 is arranged approximately parallel to the transverse direction and midway along the entire length of the side strip. Along the longitudinal direction from the forefoot 120 to the heel 140, the front half of the side strip first tilts its upper edge inward and its lower edge outward, with an angle between 75° and 85° with the horizontal direction. After passing the second horizontal strip, the rear half of the side strip tilts its upper edge outward and its lower edge inward, with an angle between 30° and 40° with the horizontal direction. The two symmetrical side strips converge at the heel 140, forming a "V" shape.

[0051] More specifically, two first deformable units 136 and two second deformable units 137 are arranged on the two side strips in the arch region, respectively, between the first horizontal strip 134 and the second horizontal strip 135, and between the second horizontal strip 135 and the heel portion 140. The first deformable unit 136 extends longitudinally along the side strip by 5 to 15 mm. Similarly, the third deformable unit 138 and the fourth deformable unit 139 are arranged midway between the first horizontal strip 134 and the second horizontal strip 135, respectively, extending transversely by 5 to 15 mm. The transverse thickness of the first deformable unit 136 or the second deformable unit 137 is less than that of the side strips on either side, with the thickness ratio of the first deformable unit 136 and the second deformable unit 137 being approximately 1:2. Likewise, the longitudinal thicknesses of the third deformation unit 138 and the fourth deformation unit 139 are both smaller than the longitudinal thicknesses of the first horizontal bar 134 and the second horizontal bar 135 on both sides thereof, and the thickness ratio between the two is approximately 1:2.

[0052] The side strips of the arch portion 130, the horizontal strips bridging the two side strips, and the deformation units located on the side strips and horizontal strips, along with the other components of the sole component 100, form a mechanically heterogeneous structure. When subjected to vertical downward pressure, the first and second horizontal strips deform laterally, causing the two side strips to deform laterally. Due to the mechanically heterogeneous structure of the sole component 100, the heel tilts forward in response to the lateral deformation of the two side strips.

[0053] The heel portion 140 of the sole component 100 according to the present invention is connected to the two side strips of the arch portion 130, and its overall shape is similar to the heel portion of the sole. The heel portion 140 is generally plate-shaped, and an elliptical third through hole 141 is arranged in its middle area.

[0054] As an embodiment of the present invention, Figure 3 As shown, a plurality of through holes are distributed on the upper, lower, and / or side surfaces of the toe portion 110, forefoot portion 120, arch portion 130, and heel portion 140 of the sole component 100 according to the present invention. The through holes are hexagonal and narrow in the longitudinal direction, giving the sole component 100 an overall mesh-like shape. The hollow through hole design adopted in the sole component 100 can, on the one hand, reduce the weight of the sole component 100, reduce production materials, and reduce production costs; on the other hand, the presence of the through holes allows the sole component 100 to have greater toughness under pressure than a solid sole component 100 while maintaining rigidity. As a result, the deformation of the sole component 100 is more consistent with expectations, and its deformation can provide stronger propulsion. At the same time, because the grooves or through-holes reduce the mass of the sole component 100, when used in conjunction with a midsole, the midsole and the overall mass of the athletic shoe including the sole component 100 can be reduced, as the midsole is typically made of a foam material and generally has a lower density than the sole component 100. As previously mentioned, when the sole thickness, propulsion, and cushioning effects of the sole on an athlete are substantially consistent, the reduced mass of the athletic shoe can improve the athlete's athletic economy and performance.

[0055] As another embodiment of the present invention, the above-mentioned sole component 100 with a hollow structure can affect the mechanical properties of the sole component such as rigidity and toughness by changing any one of the shape, size and spacing of the hollow through-holes, thereby affecting the mechanical feedback of the sole component 100 when external pressure is applied. For example, by changing the shape of the through-holes, the shape of the hollow through-holes can be changed to a regular hexagon, such as Figure 4 Or, relative to Figure 4 In the embodiment shown, the spacing of the hollow through holes is changed, such as Figure 5 As shown, the spacing between the hexagonal through holes is reduced, and the density of the hollow through holes is increased. Figure 6 The side view of the sole component 100 is shown to compare the three different shapes and spacings of the hollow holes. By changing any one of the shapes, sizes and spacings of the hollow holes, a variety of sole components 100 with different mechanical properties can be achieved to meet the needs of midsoles with different mechanical feedback. For example, Figure 5 Compared with the embodiment Figure 4In the embodiment, the shape and size of the through holes are the same, but the spacing is reduced, so the weight is relatively small, it is lighter, its toughness is relatively enhanced, and the response to the applied external force, such as the deformation of the side strips and the heel 140, is larger, but the rigidity is relatively reduced, and the support provided to the sole of the foot is reduced. Figure 3 Compared with the embodiment Figure 5 The embodiment has larger through holes and the same spacing between through holes, which is compared with Figure 5 The toughness of the embodiment shows an increasing trend, while the rigidity decreases relatively.

[0056] The sole component 100 with the above-described structure can utilize the double lever principle to provide propulsion for the user's running exercise, thereby improving their athletic performance. During the movement, the downward pressure on the arch portion 130 of the sole component 100 causes the deformation elements of the first horizontal bar 134 and the second horizontal bar 135 to deform laterally, thereby generating an outward expansion force, causing the side bars to deform outward, forming an active lever. The non-reciprocal structure of the mechanics lifts the heel portion 140, providing propulsion. At the same time, after the heel is lifted, due to the certain rigidity of the sole component 100, the sole component 100 structure forms a passive lever through force conduction and rolling effects, forming a fulcrum of the lever near the arch. Due to the pressure on the forefoot, the heel portion 140 is lifted, thereby generating forward propulsion.

[0057] like Figure 7 As shown, in another embodiment according to the present invention, a boss 151 is arranged between the toe portion 110 and the forefoot portion 120 of the sole component 100, spanning these components. The boss 151 is parallel to the plane of the sole component 100 and is located vertically above the sole component 100. The projection of the boss 151 on the plane of the sole component is substantially elliptical or rectangular with rounded corners. Four pillars 152 extend from the periphery of the boss 151. The four pillars 152 extend downward at a certain angle from the front and rear ends of both sides of the boss, respectively, to both sides of the rear end of the toe portion 110 and both sides of the front end of the forefoot portion 120 of the sole component 100. The boss 151 is connected to the sole component 100 via the four pillars 152.

[0058] When a sole having the sole component 100 described in the above embodiment is subjected to downward gravity, the boss 151 is pressed downward, and the support column then moves downward as the boss 151 is pressed downward, while exerting pressure on both sides of the sole component 100. The pressure exerted by the support column 152 of the boss 151 on both sides of the sole component 100 causes the first side strip 131 and the second side strip 132 of the sole component 100 to deform toward the sides of the sole component 100. This deformation of the first side strip 131 and the second side strip 132 is converted into a deformation that lifts the heel portion 140 of the sole component 100 upwards, thereby providing propulsion. Simultaneously, after the heel is lifted, the sole component 100 has a certain degree of rigidity, and through force conduction and rolling effects, the sole component 100 structure forms a passive lever, forming a fulcrum of the lever near the arch of the foot. Due to the pressure on the forefoot, the heel portion 140 is lifted accordingly, thereby generating a forward propulsion force.

[0059] The sole component 100 provided by the present invention is prepared by a metal additive manufacturing method, the preparation method being as follows: Figure 8 As shown in the flow chart. Specifically, the sole component 100 can be produced using metal powder laser sintering. A layer of metal powder is placed on the additive manufacturing machine's print platform, and then a laser beam is used to sinter the powder into the shape of a 3D model. Metal additive manufacturing technology can produce complex and highly detailed designs that are impossible with other technologies, breaking the limitations of traditional metal casting. Parts printed using metal laser sintering (DMLS) have excellent mechanical properties, allowing even miniature models to be created with considerable detail.

[0060] The above-mentioned sole component 100 can be manufactured by a metal additive manufacturing process, and the specific steps are as follows:

[0061] (1) A three-dimensional model of the sole component 100 is generated in a computer, and the three-dimensional model is converted into a series of two-dimensional plane models perpendicular to the laser irradiation direction using slicing software. The thickness of each cross section between the two-dimensional plane models is between 0.03 mm and 0.04 mm.

[0062] (2) Before printing, the nickel-titanium metal powder was vacuum dried in a vacuum oven at 80°C for 6-7 hours.

[0063] (3) A mixed inert gas is introduced into the AM machine as a shielding gas, wherein the mixed inert gas comprises at least two inert gases, one of which is nitrogen and the other is argon, and the volume proportion of nitrogen is 20% to 75%. After the inert gas is introduced, the oxygen content in the AM machine cavity is less than 0.1%.

[0064] (4) Metal powder is spread or applied onto the powder bed using a roller or scraper. A laser scans and melts the powder according to a slicing pattern, selectively building thin horizontal metal layers one by one. The laser power ranges from 200W to 250W, the laser scanning speed ranges from 500 to 600mm / s, and the scanning pitch ranges from 0.10mm to 0.15mm. During area scanning, the end of each scan vector pauses for 0.05 to 0.09s.

[0065] (5) The powder bed is lowered by one level, and the above process is repeated until the sole component 100 is completely constructed.

[0066] (6) The preparation method further includes a post-processing step after the printing step, wherein the nickel-titanium alloy sole component 100 obtained by the printing step is kept at a temperature within a range of 450° C. to 550° C. for 2 to 4 hours.

[0067] Metal powder bed fusion processes include direct metal laser sintering, selective laser melting, and electron beam melting. Direct metal laser sintering (DMLS) is unique in that it can be used for virtually any metal alloy, and excess powder can be recovered from the build chamber and recycled. The main advantage of DMLS is that it produces objects free of residual stress and internal defects, which is extremely important for metal parts under high stress.

[0068] Traditional manufacturing methods, such as casting, are complex for the complex geometry of the sole component 100 according to the present invention. However, metal additive manufacturing can reduce material waste by up to 90%, rapidly produce prototypes and functional components, and achieve consolidated manufacturing of parts, improving efficiency.

[0069] The sole component provided by the present invention is manufactured using metal additive manufacturing technology. Specifically, it is produced through a laser sintering process using nickel-titanium metal powder. The resulting nickel-titanium alloy sole component 100 exhibits both good rigidity and sufficient toughness, achieving a balance between rigidity and toughness. This allows the sole component to exhibit sufficient toughness to deform the side strips to lift the heel, creating an active lever, while also exhibiting sufficient rigidity to provide forward thrust through a rolling effect, creating a passive lever.

[0070] Furthermore, the nickel-titanium alloy sole component 100 provided by the present invention can be manufactured to be thinner than conventional sole components while maintaining comparable performance, such as stiffness and toughness, to conventional sole components 100. The thickness of the sole component 100 can range from 0.7 mm to 1.2 mm. The sole component 100 produced using metal additive manufacturing technology offers a high degree of design flexibility, allowing for computer-controlled adjustments to the three-dimensional model of the sole component 100, including its height (height), thickness, and local angles.

[0071] Therefore, the sole component 100 according to the present invention can be manufactured using a variety of metal additive manufacturing methods. By incorporating the properties of the metal material during the manufacturing process, the sole component 100 structure can be specifically adjusted and designed, such as by changing thickness and angles. The sole component 100 can be made of materials such as titanium alloy, stainless steel, aluminum alloy, nickel alloy, and cobalt-chromium alloy, using a metal powder laser sintering process. Preferably, the sole component 100 is manufactured using nickel-titanium metal powder additive manufacturing, where the ratio of nickel to titanium powder is 53-56 wt.% and 44-47 wt.%. Particularly preferably, the ratio of nickel to titanium powder is 55 wt.% and 45 wt.%.

[0072] soles

[0073] The present invention also provides a sports shoe sole having the aforementioned sole component 100. The sole comprises an insole, a midsole, and an outsole. The midsole comprises an upper midsole 201, a lower midsole 202, and the sole component 100. The insole is the topmost layer of the sole structure and directly contacts the sole of the foot. The upper midsole 201 and the lower midsole 202 are located above and below the sole component 100, respectively, sandwiching the sole component 100 therebetween. Together, they form the midsole portion, located below the insole. The outsole is located at the bottom of the sole and contacts the ground.

[0074] In the embodiment, the insole, upper midsole 201, sole assembly 100, lower midsole 202, and outsole of the sports shoe are bonded together using a specific adhesive. Specifically, the sports shoe includes an outsole bonded to the ground-facing side of the midsole. The outsole of a sports shoe is generally hard and wear-resistant, and the pattern and material of the surface that contacts the ground make it non-slip. The main functions of the outsole are to increase the shoe's grip on the ground, improve its durability, and also serve as a cushioning layer to at least partially absorb ground impact. However, due to its relatively heavy weight, outsoles have generally been installed only in specific wear areas in recent years, or integrated into the midsole during the manufacturing process. That is, the outsole can be integrated into the midsole as a single piece, or it can be divided into two areas, such as the forefoot and heel areas, and integrated into the midsole. The hardness of the outsole can be between 60 and 70 Shore A, and the density is preferably ≤1.5g / cm 3 ; Anti-slip performance: dry friction coefficient ≥ 0.7; wet friction coefficient ≥ 0.5.

[0075] The midsole of an athletic shoe's sole structure is located between the outsole and the upper. Its primary function is to provide cushioning, propulsion feedback, and stability during exercise, mitigating injuries to joints like the knees. The midsole absorbs and cushions the impact of the athlete's foot landing, achieving a shock-absorbing effect. The primary materials used to make midsoles can be foam materials such as polyurethane (PU), thermoplastic polyurethane (TPU), ethylene-vinyl acetate (EVA), or thermoplastic polyethylene (TPE).

[0076] like Figure 9As shown, similar to the sole component 100, the midsole has a toe area, a metatarsophalangeal joint area, an arch area, and a heel area. In order to place the above-mentioned sole component 100 structure in the midsole, the midsole is divided into an upper midsole 201 and a lower midsole 202. The upper surface shape of the upper midsole 201 corresponds to the shape of the sole of the foot, and the thickness of the forefoot area of the upper midsole 201 is greater than that of the heel area, with the thickness of the arch area forming a transition between the two. The lower side of the upper midsole 201 has a groove for accommodating the sole component 100. The shape of the groove is consistent with the outline of the sole component 100 to prevent the sole component 100 from deforming too much during exercise and causing improper displacement in the sole, which affects the performance of the sports shoes. The lower midsole 202 is designed to cooperate with the upper midsole 201 to form the midsole of the sports shoes. The upper midsole 201 is designed with specially designed grooves on its lower surface that align with the structure of the sole component 100, ensuring a better fit between the sole component 100 and the midsole. For example, the front end of the upper midsole 201 is provided with protrusions corresponding to the first groove 111 and the first through-hole 112. Grooves are arranged on both sides of the front end of the upper midsole 201, corresponding to the second groove 121 and the third groove 122. Three protrusions are arranged in the arch area of the upper midsole 201. The combined outline of the three protrusions matches the second through-hole 133, and the three protrusions are designed to secure the first horizontal bar 134 and the second horizontal bar 135 between the two protrusions. A protrusion corresponding to the third through-hole 141 is also arranged in the heel area of the rear end of the upper midsole 201 to position the heel portion 140 of the sole component 100. The above-mentioned multiple protrusions ensure that the sole component 100 is positioned at the upper midsole 201, and together with the lower midsole 202, prevent the sole component 100 from moving or slipping during the user's movement. The design of the grooves on both sides of the upper midsole 201 also makes it easier for the sole component 100 to follow the user's movement and bend between the toe portion 110 and the arch portion 130, avoiding the user from using too much extra force to bend this position and causing fatigue. Furthermore, the arch portion 130 of the sole component 100 focuses on the pressure transmitted from the sole of the foot, resulting in lateral deformation of the side strips, thereby generating a lifting force at the heel portion 140, helping to propel the user forward. Figure 10 , showing how the sole component according to the present invention is assembled with the upper midsole 201 and lower midsole 202 to form a sports shoe sole. Two bosses are provided at the front and rear ends of the upper surface of the lower midsole 202, where it meets the upper midsole 201 and sole component 100, to more stably secure the sole component 100 and provide space for deformation during movement.

[0077] On this basis, the present invention also provides a sports shoe comprising the running shoe sole described above and an upper fixedly coupled thereto. Such sports shoes may also be referred to as racing or slow-speed running shoes. Incorporating the biomechanical characteristics of human running, the present invention designs a midsole component 100 with non-reciprocal deformation units. While ensuring shock absorption, this design provides athletes with enhanced propulsion to optimize their performance. The running shoe sole structure described above, which improves running efficiency, can be used with conventional uppers and other components without particular limitation.

[0078] While the embodiments of the present invention have been illustrated and described herein, those skilled in the art will appreciate that the aforementioned and other modifications, omissions, and additions may be made without departing from the spirit and scope of the present invention. The present invention should not be limited to the specific embodiments described herein, but should be understood to encompass all possible embodiments of the features recited in the appended claims within the scope and equivalents thereof.

[0079] The dimensions and values disclosed herein should not be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise indicated, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "approximately 40 mm."

[0080] All documents cited in the "Detailed Description" are, in relevant part, incorporated herein by reference; the citation of any document shall not be construed as an admission that it is prior art with respect to the present invention. To the extent any meaning or definition of a term in this written document conflicts with any meaning or definition of the term in a document incorporated by reference, the meaning or definition assigned to the term in this written document shall govern.

[0081] Although specific embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that various other changes and modifications may be made without departing from the spirit and scope of the present invention. Therefore, it is intended that all such changes and modifications within the scope of the present invention be encompassed in the appended claims.

Claims

1. A sole component for sports shoes, which is used in a sole structure and has a longitudinal direction and a lateral direction perpendicular to each other, and a vertical direction perpendicular to the longitudinal direction and the lateral direction, characterized in that: The sole component includes, from front to back in the longitudinal direction, a toe portion corresponding to the shape of the plantar toe area, a forefoot portion connected to the toe portion and corresponding to the plantar metatarsophalangeal joint area, a heel portion corresponding to the plantar heel area, and an arch portion having a hollow area bridging the forefoot portion and the heel portion; The arch portion includes a pair of side strips extending from the lateral sides of the rear end of the forefoot portion to the lateral sides of the front end of the heel portion; a first transverse strip disposed transversely near the forefoot portion and designed to connect the side strips on both sides in a transverse direction; and a second horizontal strip located on the side of the arch of the foot near the heel and designed to connect the side strips on both sides in the horizontal direction; The sole component is entirely made of metal material additive manufacturing, wherein the metal material includes one or more of titanium alloy, nickel alloy, stainless steel, aluminum alloy and cobalt-chromium alloy.

2. The sole component according to claim 1, characterized in that The toe portion and forefoot portion further include a boss spanning them, the boss being parallel to the plane of the sole component and vertically located above the sole component, and a plurality of struts extending downward at a certain angle from the front and rear ends of both sides of the boss, the struts extending to both sides of the rear end of the toe portion and both sides of the front end of the forefoot portion to be connected to the sole component.

3. The sole component according to claim 1, wherein: The sole component is made of nickel-titanium metal powder additive manufacturing, wherein the ratio of nickel to titanium powder is 53-56wt.%, and 44-47wt.% by weight.

4. The sole component according to claim 3, characterized in that The sole component is made of nickel-titanium metal powder additive manufacturing, wherein the ratio of nickel to titanium powder is 55wt.% and 45wt.% by weight.

5. The sole component according to claim 1, characterized in that The vertical thickness of the sole component is designed to be between 0.7 mm and 1.2 mm.

6. The sole component according to claim 1, characterized in that Through holes are distributed on the upper surface, the lower surface and / or the side surface of the sole component, wherein any one of the shapes, sizes and mutual distances of the through holes is adjustable.

7. A method for manufacturing a sole component for sports shoes according to any one of claims 1 to 6, characterized in that: The steps include: Step 1. Generate a 3D model of the sole component on a computer and use slicing software to convert the 3D model into a series of 2D plane models perpendicular to the laser irradiation direction; Step 2. Before printing, vacuum dry the nickel-titanium metal powder in a vacuum oven at no less than 80°C for 6-7 hours. Step 3. Introducing a mixed inert gas as a shielding gas into the additive manufacturing machine, wherein the mixed inert gas comprises at least two inert gases, one of which is nitrogen, and the volume proportion of nitrogen is 20% to 75%; Step 4. Metal powder is spread or applied onto the powder bed using a roller or scraper. The laser scans and melts the powder according to the slicing pattern, selectively building thin horizontal metal layers one by one. Step 5. The powder bed is lowered one level and the above process is repeated until the sole component is completely built. Step 6: post-treating the prepared sole component by keeping it at a temperature range of 450° C. to 550° C. for 2 to 4 hours.

8. The method for manufacturing a sole component according to claim 7, wherein: In step 1, the distance between the layered slices is between 0.03 mm and 0.04 mm.

9. The method for manufacturing a sole component according to claim 7, wherein: During the laser scanning process, the forming parameters include laser power, which is in the range of 200W-250W, laser scanning speed, which is in the range of 500mm / s-600mm / s, and scanning spacing, which is in the range of 0.10mm-0.15mm.

10. A sole structure comprising an upper midsole and a lower midsole that are cooperatively connected to each other, a sole component built between the upper midsole and the lower midsole, and a shoe outsole, characterized in that: The sole component is the sole component for sports shoes according to any one of claims 1 to 6, and any one of the upper midsole and the lower midsole is provided with a groove for accommodating the sole component, wherein the shape of the groove is designed to be consistent with the contour of the sole component.

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