A thin and light stitched shoe midsole non-woven fabric and its preparation method and application

Abstract

This invention provides a lightweight, thin, stitch-knitted shoe midsole nonwoven fabric, its preparation method, and its application, relating to the field of midsole fabric technology. The lightweight, thin, stitch-knitted shoe midsole nonwoven fabric is obtained by weaving and setting 40wt%-60wt% high-strength DTY yarn and 60wt%-40wt% high-strength FDY fiber; the thickness of the midsole nonwoven fabric is 0.4-0.8mm. This invention obtains the midsole fabric by mixing high-strength DTY yarn and high-strength FDY fiber in a specific ratio, followed by weaving and setting. The high elasticity of DTY complements the high strength and low shrinkage of FDY, achieving a balance between the contradictory properties of "lightweight and strong," thus enabling the midsole fabric to maintain good abrasion resistance, tensile strength, and burst strength while reducing thickness and weight.

Description

Technical Field

[0001] This invention relates to the field of midsole fabric technology, and in particular to a thin and lightweight nonwoven fabric for stitched shoe midsoles, its preparation method, and its application. Background Art

[0002] The midsole fabric is a key lining material in the shoe manufacturing process. It is located between the midsole (or outsole) and the upper of the shoe and mainly plays a role in connection, support, cushioning and transition.

[0003] As people's pursuit of quality of life continues to improve, the market demand for shoe midsole fabrics is also increasing. Currently, the main shortcomings of popular midsole fabrics on the market include poor abrasion resistance, low softness, and poor puncture resistance. To enhance the abrasion resistance and strength of the midsole fabric, the common practice is to increase its thickness; however, this affects the breathability and comfort of the shoe. In other words, balancing the thinness and strength of the midsole fabric is currently a key technical challenge in this field. Summary of the Invention

[0004] This invention provides a lightweight stitched nonwoven fabric for shoe midsoles, its preparation method, and its application, in order to solve the defects of existing midsole fabrics that cannot achieve both lightness and strength, thereby achieving lightweight while still obtaining midsole nonwoven fabrics with good wear resistance and strength.

[0005] In a first aspect, the present invention provides a thin and lightweight nonwoven fabric for the midsole of a sewn-knitted shoe, which is obtained by weaving and shaping 40wt%-60wt% high-strength DTY yarn and 60wt%-40wt% high-strength FDY fiber; the thickness of the nonwoven fabric for the midsole is 0.4-0.8mm.

[0006] The thin and light nonwoven fabric for the midsole of the shoe provided by the present invention has a thickness of 0.6±0.05mm and is obtained by weaving and shaping 50±3wt% high-strength DTY yarn and 50±3wt% high-strength FDY fiber.

[0007] The lightweight stitched nonwoven fabric for shoe midsoles provided by the present invention has a basis weight of 250-300 g / m², a tensile strength ≥300 N / 2.54 cm (GT / B3923.1-2013), and a bursting strength ≥25 kgf / cm². 2 (GB / T7742.1-2005), abrasion resistance ≥8000 revolutions (Martindale test).

[0008] The thin and light nonwoven fabric for the midsole of the shoe provided by the present invention has a high-strength DTY yarn with a fineness of 200D and a crimp shrinkage rate of 15%-25%.

[0009] The thin and light stitched shoe midsole nonwoven fabric provided by the present invention is a high-strength DTY yarn that is a large bright triangular shaped yarn.

[0010] The thin and light stitched nonwoven fabric for shoe midsoles provided by the present invention has a tensile strength of high-strength FDY fibers ≥4.5cN / dtex and a heat shrinkage rate ≤5%.

[0011] The thin, nonwoven fabric for the midsole of a stitched shoe provided by the present invention comprises high-strength FDY fiber, which is polyester fiber.

[0012] Secondly, the present invention provides the application of the above-mentioned lightweight stitched shoe midsole nonwoven fabric in footwear products.

[0013] Thirdly, the present invention provides a method for preparing the above-mentioned thin and light stitched shoe midsole nonwoven fabric.

[0014] The preparation method provided by the present invention includes: mixing, opening, combing and laying 40wt%-60wt% high-strength DTY yarn and 60wt%-40wt% high-strength FDY fiber to obtain a fiber web, then performing two stitch-knitting operations to obtain a grey fabric, and then impregnating the obtained grey fabric with acrylic emulsion and setting it at high temperature.

[0015] According to the preparation method provided by the present invention, in the carding process, the main cylinder speed of the carding machine is 1200±10 Hz, and the main cylinder working roller speed is 18±2 Hz;

[0016] In the web laying process, the reciprocating speed of the web laying machine is as follows: speed 1 is 1.3 Hz, speed 2 is 1.2 Hz, speed 3 is 1.1 Hz, speed 4 is 1.0 Hz, speed 5 is 1.0 Hz, speed 6 is 1.2 Hz, speed 7 is 1.3 Hz, and speed 8 is 1.4 Hz; the speed of the compensation roller is the same as the speed of the reciprocating screen.

[0017] The material produced by the carding machine is conveyed to the web laying machine through a conveyor curtain. The parameters of the conveyor curtain are: conveyor curtain speed: 16±1 Hz, compensation curtain speed: 14±1 Hz.

[0018] According to the preparation method provided by the present invention, in the sewing process, the stitch length is 4-8 stitches / cm and the thread tension is 15-35cN.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] This invention provides a lightweight, thin, nonwoven fabric for shoe midsoles, its preparation method, and its application. The midsole fabric is obtained by mixing high-strength DTY yarn and high-strength FDY fiber in a specific ratio, followed by weaving and shaping. The high elasticity of DTY complements the high strength and low shrinkage of FDY, achieving a balance between the contradictory properties of "lightweight and strong". This allows the midsole fabric to maintain good abrasion resistance, tensile strength, and burst strength while reducing thickness and weight. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this invention, not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0022] The endpoints and any values ​​of the ranges disclosed herein are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be considered as specifically disclosed herein.

[0023] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "specific implementation," or "some specific implementations," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0024] Where specific techniques or conditions are not specified in the examples, they shall be performed in accordance with the techniques or conditions described in the literature in this field, or in accordance with the product instructions. Reagents or instruments whose manufacturers are not specified are all conventional products that can be purchased through legitimate channels.

[0025] This invention provides a lightweight nonwoven fabric for the midsole of a sewn-in shoe, which is obtained by weaving and shaping 40wt%-60wt% high-strength DTY yarn and 60wt%-40wt% high-strength FDY fiber; the thickness of the nonwoven fabric for the midsole is 0.4-0.8mm.

[0026] DTY (Draw Textured Yarn) is produced by stretching and false-twisting POY on a texturing machine. DTY yarn is characterized by its bulkiness, softness, elasticity, good hand feel, excellent coverage, and improved moisture absorption and breathability (compared to FDY). High-strength DTY yarn refers to DTY yarn with higher breaking strength and toughness than ordinary DTY.

[0027] FDY (Fully Drawn Yarn) is a type of FDY fiber that completes the entire process from spinning, drawing to heat setting in a single step. FDY fibers are characterized by high orientation, high crystallinity, high strength, high modulus, low elongation, dense structure, and good dimensional stability. High-strength FDY fibers refer to FDY fibers with higher breaking strength and modulus than ordinary FDY fibers.

[0028] This invention mixes high-strength DTY yarn and high-strength FDY fiber in a specific ratio, and then weaves and shapes them to obtain a midsole fabric. The high elasticity of DTY complements the high strength and low shrinkage of FDY, achieving a balance between the contradictory properties of "lightweight and strong". This allows the midsole fabric to maintain good abrasion resistance, tensile strength and burst strength while reducing thickness and weight.

[0029] In a preferred embodiment of the present invention, the thin and lightweight stitched shoe midsole nonwoven fabric is obtained by weaving and shaping 50±3wt% high-strength DTY yarn and 50±3wt% high-strength FDY fiber. The thickness of the midsole nonwoven fabric is 0.6±0.05mm.

[0030] Furthermore, in a preferred embodiment of the present invention, the basis weight of the nonwoven fabric in the midsole is 250-300 g / m², the tensile strength is ≥300 N / 2.54 cm (GT / B3923.1-2013), and the bursting strength is ≥25 kgf / cm². 2 (GB / T7742.1-2005), abrasion resistance ≥8000 revolutions (Martindale test).

[0031] In some embodiments of the present invention, the fineness of the high-strength DTY yarn is 200D, and its crimp shrinkage rate is 15%-25%.

[0032] In the above technical solution, the 200D fineness provides sufficient monofilament stiffness to ensure that the crimped structure does not collapse irreversibly under weaving tension; the crimp shrinkage rate of 15%-25% allows the yarn to maintain high strength characteristics (≥4.0cN / dtex) while still possessing a certain soft touch required for textile products, thus achieving the fineness-cracking synergistic effect.

[0033] Furthermore, in some embodiments of the present invention, the high-strength DTY yarn is a large bright triangular profile yarn.

[0034] The inherent crimp structure of DTY yarn endows it with excellent bulk, coverage, and elasticity. The triangular cross-section further enhances the yarn's fullness and volume, resulting in a fuller, thicker, and softer feel in the final fabric, improving wearing comfort and quality. The "high-gloss" characteristic, a special optical effect, gives the yarn and final fabric a beautiful sheen ("high-gloss effect"). While "high-gloss" usually focuses more on appearance, this structural characteristic brings certain functional (moisture-wicking and quick-drying) potential to the fabric. Working synergistically with the triangular cross-section, the grooved structure formed by the triangular cross-section facilitates the formation of capillary channels between fibers, which enhances the wicking capacity of the yarn and fabric, promoting the rapid diffusion and evaporation of sweat or moisture along the fiber's longitudinal direction. This invention uses high-strength DTY yarn with high-gloss triangular cross-section yarn, offering additional advantages, especially when the product is used in sports or outdoor clothing.

[0035] In some embodiments of the present invention, the high-strength FDY fiber has a breaking strength ≥4.5cN / dtex and a heat shrinkage rate ≤5%.

[0036] In the above technical solution, high tensile strength means that the fiber can withstand huge tensile force without breaking, has high durability, can resist wear and impact during long-term use, and is conducive to achieving lightweight and improving processing performance. However, the heat shrinkage rate affects dimensional stability. The present invention has found that selecting high-strength FDY fibers with tensile strength and heat shrinkage rate within the above range can make the resulting midsole fabric have better strength and production stability.

[0037] In some embodiments of the present invention, the high-strength FDY fiber is polyester fiber.

[0038] To further conserve energy and promote environmentally friendly production, the high-strength FDY fiber and high-strength DTY yarn used in this invention are preferably made from recyclable raw materials. This saves resources, minimizes environmental pollution, and meets the requirements for energy conservation and emission reduction.

[0039] Secondly, the present invention provides the application of the above-mentioned lightweight stitched shoe midsole nonwoven fabric in footwear products.

[0040] This invention leverages the advantages of applying the aforementioned lightweight, stitched nonwoven fabric for shoe midsoles in footwear, perfectly meeting the comprehensive demands of modern footwear for lightweight, high performance, comfort, and aesthetics. These advantages include: significant weight reduction, enhancing comfort and athletic performance; high strength providing stable support, lasting rebound, and extended lifespan; a porous, moisture-wicking structure for superior breathability and sweat-wicking; effective shock absorption to protect foot joints; a unique, high-gloss finish that brings a revolutionary aesthetic breakthrough to sole design; and ease of processing, adapting to various shoe manufacturing processes. Specifically, it can be applied to high-end running / training shoes, fashionable sports / casual shoes, lightweight commuter / walking shoes, and children's shoes.

[0041] Thirdly, the present invention provides a method for preparing the above-mentioned thin and light stitched shoe midsole nonwoven fabric.

[0042] The preparation method provided by the present invention includes: mixing, opening, combing and laying 40wt%-60wt% high-strength DTY yarn and 60wt%-40wt% high-strength FDY fiber to obtain a fiber web, then performing two stitch-knitting operations to obtain a grey fabric, and then impregnating the obtained grey fabric with acrylic emulsion and setting it at high temperature.

[0043] In the above preparation method, the mixing, opening, carding, and web-laying processes ensure the uniform dispersion and directional arrangement of fibers. The stitch-bonding process, using sewing thread to hook, wrap, and bind the fibers in the web into a whole, offers significant advantages with two stitch-bonding steps: the first stitch-bonding forms the basic skeleton, providing initial strength and dimensional stability; the second stitch-bonding reinforces and refines the first step, significantly improving the fabric's uniformity, density, anti-delamination, and overall strength. This "double insurance" mechanism ensures a very robust fabric structure, capable of withstanding significant stress even when thin, and is not easily deformed or torn, laying a solid foundation for the final lightweight, high-strength product. Acrylic emulsion impregnation allows the acrylic emulsion to penetrate into the fiber gaps and stitch-bonded structure, curing into a film after high-temperature setting, encapsulating and bonding the fibers and stitch-bonded threads. This is equivalent to forming a continuous polymer network throughout the nonwoven fabric's interior and surface, greatly enhancing the bonding force between fibers, interlayer bonding force, stiffness, dimensional stability, and abrasion resistance, further improving mechanical properties, while also giving the material a certain degree of rigidity and support.

[0044] In other words, the preparation method of the present invention, combined with a specific fiber combination, significantly reduces the thickness and weight while improving the strength of the material, perfectly meeting the core requirement of "lightweight midsole" in midsole fabric. It achieves an excellent balance of key properties such as high strength, high toughness, high dimensional stability, and good abrasion resistance. Moreover, the production process of the present invention is efficient, continuous, and controllable, with good cost-effectiveness and environmental friendliness.

[0045] In some embodiments of the present invention, in the combing process, the main cylinder speed of the combing machine is 1200±10 Hz, and the main cylinder working roller speed is 18±2 Hz;

[0046] In the web laying process, the reciprocating speed of the web laying machine is as follows: speed 1 is 1.3 Hz, speed 2 is 1.2 Hz, speed 3 is 1.1 Hz, speed 4 is 1.0 Hz, speed 5 is 1.0 Hz, speed 6 is 1.2 Hz, speed 7 is 1.3 Hz, and speed 8 is 1.4 Hz; the speed of the compensation roller is the same as the speed of the reciprocating screen.

[0047] The material produced by the carding machine is conveyed to the web laying machine through a conveyor curtain. The parameters of the conveyor curtain are: conveyor curtain speed: 16±1 Hz, compensation curtain speed: 14±1 Hz.

[0048] In some embodiments of the present invention, the stitch length in the sewing process is 4-8 stitches / cm and the thread tension is 15-35cN.

[0049] In the stitch-knitting process, the stitch length directly determines the density and fiber entanglement of the stitch-knitted structure, thus affecting the mechanical properties and uniformity of the fabric. The stitch length also affects the penetration depth and distribution uniformity of the acrylic emulsion, requiring coordination with the impregnation process. The thread tension controls the tightness and shape of the stitch-knitted loops, directly affecting the dimensional stability and structural integrity of the fabric. This invention has found that controlling the stitch length and thread tension within the aforementioned ranges yields a midsole nonwoven fabric with excellent overall performance.

[0050] More preferably, in the first stitching, the stitch length is 4-5.5 stitches / cm and the thread tension is 15-25cN; in the second stitching, the stitch length is 6-8 stitches / cm and the thread tension is 25-35cN.

[0051] To facilitate understanding of the lightweight stitched shoe midsole nonwoven fabric and its preparation method provided by the present invention, the following description is provided through some specific embodiments and comparative examples.

[0052] Example 1

[0053] This embodiment provides a nonwoven midsole fabric with a thickness of 0.6 mm, obtained by weaving and setting 50 wt% high-strength DTY yarn and 50 wt% high-strength FDY fiber. The high-strength DTY yarn is a bright triangular profiled yarn with a fineness of 200D and a crimp shrinkage rate of 15%-25%; the high-strength FDY fiber is polyester fiber with a breaking strength ≥4.5 cN / dtex and a heat shrinkage rate ≤5%.

[0054] The specific preparation steps are as follows:

[0055] (1) 50wt% high-strength DTY yarn and 50wt% high-strength FDY fiber are fed into a cotton mixer for opening and mixing, and then further mixed in a large-scale cotton mixer. After that, they are fed into an opening machine for full opening. After opening, they are fed into a carding machine. The carded fiber web is conveyed to a web laying machine through a conveyor curtain. The web laying machine reciprocates to form layers of superimposed fiber web. The fiber web is then conveyed to a sewing machine through a leather curtain. The main cylinder speed of the carding machine is 1200 rpm. The main cylinder working roller speed is 18 Hz; the reciprocating curtain speeds of the screen laying machine are: speed 1 is 1.3 Hz, speed 2 is 1.2 Hz, speed 3 is 1.1 Hz, speed 4 is 1.0 Hz, speed 5 is 1.0 Hz, speed 6 is 1.2 Hz, speed 7 is 1.3 Hz, and speed 8 is 1.4 Hz; the compensation roller speed is the same as the reciprocating curtain speed; the parameters of the conveyor curtain are: conveyor curtain speed: 16 Hz, compensation curtain speed: 14 Hz.

[0056] (2) The fiber web obtained in step (1) is sewn for the first time using a high-speed sewing machine with a stitch length of 4.5 stitches / cm and a thread tension of 20cN. After the first sewing is completed, a second sewing is performed with a stitch length of 7.2 stitches / cm and a thread tension of 30cN to obtain the greige fabric.

[0057] (3) The fabric obtained in step (2) is impregnated with acrylic emulsion to fully fill the fibers. Then, the excess emulsion is squeezed out with a rolling mill and then dried and shaped at high temperature to form rolls.

[0058] Example 2

[0059] This embodiment provides a nonwoven midsole fabric with a thickness of 0.7 mm, obtained by weaving and setting 60 wt% high-strength DTY yarn and 40 wt% high-strength FDY fiber. The high-strength DTY yarn is a bright triangular profiled yarn with a fineness of 200D and a crimp shrinkage rate of 15%-25%; the high-strength FDY fiber is polyester fiber with a breaking strength ≥4.5 cN / dtex and a heat shrinkage rate ≤5%.

[0060] The specific preparation steps are as follows:

[0061] (1) 60wt% high-strength DTY yarn and 40wt% high-strength FDY fiber are fed into a cotton mixer for opening and mixing, and then further mixed in a large-scale cotton mixer. After that, they are fed into an opening machine for full opening. After opening, they are fed into a carding machine. The carded fiber web is conveyed to a web laying machine through a conveyor curtain. The web laying machine reciprocates to form layers of superimposed fiber web. The fiber web is then conveyed to a sewing machine through a leather curtain. The main cylinder speed of the carding machine is 1200 rpm. The main cylinder working roller speed is 18 Hz; the reciprocating curtain speeds of the screen laying machine are: speed 1 is 1.3 Hz, speed 2 is 1.2 Hz, speed 3 is 1.1 Hz, speed 4 is 1.0 Hz, speed 5 is 1.0 Hz, speed 6 is 1.2 Hz, speed 7 is 1.3 Hz, and speed 8 is 1.4 Hz; the compensation roller speed is the same as the reciprocating curtain speed; the parameters of the conveyor curtain are: conveyor curtain speed: 16 Hz, compensation curtain speed: 14 Hz.

[0062] (2) The fiber web obtained in step (1) is sewn for the first time using a high-speed sewing machine with a stitch length of 4.5 stitches / cm and a thread tension of 20cN. After the first sewing is completed, a second sewing is performed with a stitch length of 7.2 stitches / cm and a thread tension of 30cN to obtain the greige fabric.

[0063] (3) The fabric obtained in step (2) is impregnated with acrylic emulsion to fully fill the fibers. Then, the excess emulsion is squeezed out with a rolling mill and then dried and shaped at high temperature to form rolls.

[0064] Example 3

[0065] This embodiment provides a nonwoven midsole fabric with a thickness of 0.5 mm, obtained by weaving and setting 40 wt% high-strength DTY yarn and 60 wt% high-strength FDY fiber. The high-strength DTY yarn is a bright triangular profiled yarn with a fineness of 200D and a crimp shrinkage rate of 15%-25%; the high-strength FDY fiber is polyester fiber with a breaking strength ≥4.5 cN / dtex and a heat shrinkage rate ≤5%.

[0066] The specific preparation steps are as follows:

[0067] (1) 40wt% high-strength DTY yarn and 60wt% high-strength FDY fiber are fed into a cotton mixer for opening and mixing, and then further mixed in a large-scale cotton mixer. After that, they are fed into an opening machine for full opening. After opening, they are fed into a carding machine. The carded fiber web is conveyed to a web laying machine through a conveyor curtain. The web laying machine reciprocates to form layers of superimposed fiber web. The fiber web is then conveyed to a sewing machine through a leather curtain. The main cylinder speed of the carding machine is 1200 rpm. The main cylinder working roller speed is 18 Hz; the reciprocating curtain speeds of the screen laying machine are: speed 1 is 1.3 Hz, speed 2 is 1.2 Hz, speed 3 is 1.1 Hz, speed 4 is 1.0 Hz, speed 5 is 1.0 Hz, speed 6 is 1.2 Hz, speed 7 is 1.3 Hz, and speed 8 is 1.4 Hz; the compensation roller speed is the same as the reciprocating curtain speed; the parameters of the conveyor curtain are: conveyor curtain speed: 16 Hz, compensation curtain speed: 14 Hz.

[0068] (2) The fiber web obtained in step (1) is sewn for the first time using a high-speed sewing machine with a stitch length of 4.5 stitches / cm and a thread tension of 20cN. After the first sewing is completed, a second sewing is performed with a stitch length of 7.2 stitches / cm and a thread tension of 30cN to obtain the greige fabric.

[0069] (3) The fabric obtained in step (2) is impregnated with acrylic emulsion to fully fill the fibers. Then, the excess emulsion is squeezed out with a rolling mill and then dried and shaped at high temperature to form rolls.

[0070] Example 4

[0071] This embodiment provides a nonwoven midsole fabric with a thickness of 0.6 mm, obtained by weaving and setting 50 wt% high-strength DTY yarn and 50 wt% high-strength FDY fiber. The high-strength DTY yarn is a matte circular cross-section filament with a fineness of 200D and a crimp shrinkage rate of 15%-25%; the high-strength FDY fiber is polyester fiber with a breaking strength ≥4.5 cN / dtex and a heat shrinkage rate ≤5%. Its preparation method is the same as in Example 1.

[0072] Example 5

[0073] This embodiment provides a nonwoven midsole fabric with a thickness of 0.6 mm, obtained by weaving and setting 50 wt% high-strength DTY yarn and 50 wt% high-strength FDY fiber. The high-strength DTY yarn is a bright triangular profiled yarn with a fineness of 200D and a crimp shrinkage rate of 15%-25%; the high-strength FDY fiber is polyester fiber with a breaking strength of 3.5 cN / dtex and a heat shrinkage rate of 7%. Its preparation method is the same as in Example 1.

[0074] Example 6

[0075] This embodiment provides a nonwoven midsole fabric with a thickness of 0.6 mm, obtained by weaving and setting 50 wt% high-strength DTY yarn and 50 wt% high-strength FDY fiber. The high-strength DTY yarn is a bright triangular profiled yarn with a fineness of 200D and a crimp shrinkage rate of 15%-25%; the high-strength FDY fiber is polyester fiber with a breaking strength ≥4.5 cN / dtex and a heat shrinkage rate ≤5%.

[0076] The specific preparation steps are as follows:

[0077] (1) 50wt% high-strength DTY yarn and 50wt% high-strength FDY fiber are put into a cotton mixer for opening and mixing, and then further mixed in a large warehouse cotton mixer, and then put into an opening machine for full opening. After opening, the fiber web is put into a carding machine. The carded fiber web is conveyed to a web laying machine through a conveyor curtain. The web laying machine reciprocates to form a layered fiber web. The fiber web is conveyed to a sewing machine through a leather curtain. The main cylinder speed of the carding machine is 1400 Hz, and the main cylinder working roller speed is 20 Hz. The reciprocating curtain speed of the web laying machine is: speed 1 to speed 8 are all 1.2 Hz. The compensation roller speed is the same as the reciprocating curtain speed. The parameters of the conveyor curtain are: conveyor curtain speed: 16 Hz, compensation curtain speed: 14 Hz.

[0078] (2) The fiber web obtained in step (1) is sewn for the first time using a high-speed sewing machine with a stitch length of 4.5 stitches / cm and a thread tension of 20cN. After the first sewing is completed, a second sewing is performed with a stitch length of 7.2 stitches / cm and a thread tension of 30cN to obtain the greige fabric.

[0079] (3) The fabric obtained in step (2) is impregnated with acrylic emulsion to fully fill the fibers. Then, the excess emulsion is squeezed out with a rolling mill and then dried and shaped at high temperature to form rolls.

[0080] Example 7

[0081] This embodiment provides a nonwoven midsole fabric with a thickness of 0.6 mm, obtained by weaving and setting 50 wt% high-strength DTY yarn and 50 wt% high-strength FDY fiber. The high-strength DTY yarn is a bright triangular profiled yarn with a fineness of 200D and a crimp shrinkage rate of 15%-25%; the high-strength FDY fiber is polyester fiber with a breaking strength ≥4.5 cN / dtex and a heat shrinkage rate ≤5%.

[0082] The specific preparation steps are as follows:

[0083] (1) 50wt% high-strength DTY yarn and 50wt% high-strength FDY fiber are fed into a cotton mixer for opening and mixing, and then further mixed in a large-scale cotton mixer. After that, they are fed into an opening machine for full opening. After opening, they are fed into a carding machine. The carded fiber web is conveyed to a web laying machine through a conveyor curtain. The web laying machine reciprocates to form layers of superimposed fiber web. The fiber web is then conveyed to a sewing machine through a leather curtain. The main cylinder speed of the carding machine is 1200 rpm. The main cylinder working roller speed is 18 Hz; the reciprocating curtain speeds of the screen laying machine are: speed 1 is 1.3 Hz, speed 2 is 1.2 Hz, speed 3 is 1.1 Hz, speed 4 is 1.0 Hz, speed 5 is 1.0 Hz, speed 6 is 1.2 Hz, speed 7 is 1.3 Hz, and speed 8 is 1.4 Hz; the compensation roller speed is the same as the reciprocating curtain speed; the parameters of the conveyor curtain are: conveyor curtain speed: 16 Hz, compensation curtain speed: 14 Hz.

[0084] (2) The fiber web obtained in step (1) is sewn for the first time using a high-speed sewing machine with a stitch length of 6 stitches / cm and a thread tension of 20cN. After the first sewing is completed, a second sewing is performed with a stitch length of 6 stitches / cm and a thread tension of 20cN to obtain the greige fabric.

[0085] (3) The fabric obtained in step (2) is impregnated with acrylic emulsion to fully fill the fibers. Then, the excess emulsion is squeezed out with a rolling mill and then dried and shaped at high temperature to form rolls.

[0086] Comparative Example 1

[0087] This comparative example provides a nonwoven midsole fabric with a thickness of 0.6 mm, obtained by weaving and setting 80 wt% high-strength DTY yarn and 20 wt% high-strength FDY fiber. The high-strength DTY yarn is a bright triangular profiled yarn with a fineness of 200D and a crimp shrinkage rate of 15%-25%; the high-strength FDY fiber is polyester fiber with a breaking strength ≥4.5 cN / dtex and a heat shrinkage rate ≤5%. Its preparation method is the same as in Example 1.

[0088] Comparative Example 2

[0089] This comparative example provides a nonwoven midsole fabric with a thickness of 0.6 mm. It is made by mixing, opening, carding, and laying 50 wt% high-strength DTY yarn and 50 wt% high-strength FDY fiber to obtain a web, which is then thermally bonded. The high-strength DTY yarn is a bright triangular profiled yarn with a fineness of 200D and a crimp shrinkage rate of 15%-25%; the high-strength FDY fiber is polyester fiber with a breaking strength ≥4.5 cN / dtex and a heat shrinkage rate ≤5%.

[0090] The specific preparation steps are as follows:

[0091] (1) 50wt% high-strength DTY yarn and 50wt% high-strength FDY fiber are fed into a cotton mixer for opening and mixing, and then further mixed in a large-scale cotton mixer. After that, they are fed into an opening machine for full opening. After opening, they are fed into a carding machine. The carded web is conveyed to a web laying machine through a conveyor curtain. The web laying machine reciprocates to form a layered web. The main cylinder speed of the carding machine is 1200 Hz. The working roller speed is 18 Hz; the reciprocating curtain speeds of the screen laying machine are: speed 1 is 1.3 Hz, speed 2 is 1.2 Hz, speed 3 is 1.1 Hz, speed 4 is 1.0 Hz, speed 5 is 1.0 Hz, speed 6 is 1.2 Hz, speed 7 is 1.3 Hz, and speed 8 is 1.4 Hz; the compensation roller speed is the same as the reciprocating curtain speed; the parameters of the conveyor curtain are: conveyor curtain speed: 16 Hz, compensation curtain speed: 14 Hz.

[0092] (2) Add 15% low melting point fiber to the fiber web obtained in step (1) and perform hot air bonding.

[0093] Performance testing

[0094] Test basis:

[0095] Gram weight: Tested according to GB / T4669-2008.

[0096] Bursting strength: This indicator represents the maximum pressure the fabric can withstand before bursting, directly affecting the puncture resistance of the insole and backing fabric. Testing is conducted according to GB / T7742.1-2005, with a standard value of ≥25 kgf / cm². 2 .

[0097] Longitudinal tensile strength: GB / T 3923.1-2013, standard value ≥250N / 2.54cm.

[0098] Transverse tensile strength: GB / T 3923.1-2013, standard value ≥200N / 2.54cm.

[0099] Longitudinal 100N constant strength elongation: GB / T 3923.1-2013, standard value ≤5%.

[0100] Transverse 100N constant strength elongation: GB / T 3923.1-2013, standard value ≤15%.

[0101] Abrasion resistance: The test method refers to GB / T 3903.16-2008, the Martindale test. The Martindale test is an internationally recognized standardized test method for the abrasion resistance, pilling resistance, and appearance retention of fabrics, widely used in the durability evaluation of textiles, leather, nonwovens, and other materials. Specifically, the sample is fixed on a platform and subjected to Lissajous figure-element friction (multi-directional cyclic motion) under a set pressure (9 kPa) using a standard abrasive (such as wool felt), simulating the complex wear and tear of actual use. The number of friction cycles (revolutions) when the fabric develops a hole is recorded; the higher the value, the greater the abrasion resistance.

[0102] Moisture absorption: Used to evaluate the ability of midsole nonwoven fabric to absorb and transfer liquid water (sweat), which is key to the feeling of dryness of the feet. The test is based on GB / T21655.1-2008, and the results are expressed as wicking height (mm). The higher the value, the faster the material absorbs and transports liquid water vertically and the stronger its ability.

[0103] The test results are shown in Table 1.

[0104] Table 1

[0105]

[0106] The results above show that the nonwoven midsole fabrics of Examples 1-3 of this invention have superior overall performance, with Example 1 being the best. In Example 4, the high-strength DTY yarn did not use large-bright triangular profile yarns, resulting in poor moisture absorption of the obtained midsole fabric. In Example 5, the breaking strength and heat shrinkage rate of the high-strength FDY fiber were not within the optimal range, resulting in a midsole fabric with inferior overall performance compared to Example 1. In Examples 6 and 7, due to different preparation parameters, the overall performance was inferior to Example 1. Comparative Example 1 did not use the formulation of this invention, and the ratio of the two fibers was not within the specific ratio of this invention. Even with the same preparation method, the beneficial effects of Example 1 were not achieved. Although Comparative Example 2 used the same formulation as Example 1, the preparation steps involved direct thermal bonding after obtaining the fiber web, rather than the secondary stitching and acrylic emulsion impregnation and drying of this invention. Therefore, the performance of the resulting product was also poor.

[0107] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A lightweight, non-woven fabric for the midsole of a stitched shoe, characterized in that, The fabric is made by mixing, opening, carding, and laying 40wt%-60wt% high-strength DTY yarn and 60wt%-40wt% high-strength FDY fiber to obtain a fiber web, which is then stitched twice to obtain a grey fabric. The resulting grey fabric is then impregnated with acrylic emulsion and set at high temperature. The high-strength DTY yarn is a bright triangular profile yarn with a fineness of 200D and a crimp shrinkage rate of 15%-25%. The high-strength FDY fiber has a breaking strength ≥4.5cN / dtex and a heat shrinkage rate ≤5%. The thickness of the insole nonwoven fabric is 0.4-0.8mm.

2. The lightweight stitched nonwoven fabric for shoe midsole according to claim 1, characterized in that, The thickness of the nonwoven fabric in the insole is 0.6±0.05mm, and it is obtained by weaving and shaping 50±3wt% high-strength DTY yarn and 50±3wt% high-strength FDY fiber.

3. The lightweight stitched nonwoven fabric for shoe midsole according to claim 2, characterized in that, The nonwoven fabric of the midsole has a basis weight of 250-300 g / m², a tensile strength ≥300 N / 2.54 cm, and a bursting strength ≥25 kgf / cm². 2 Wear resistance ≥8000 revolutions.

4. The application of the lightweight stitched shoe midsole nonwoven fabric according to any one of claims 1-3 in footwear products.

5. The method for preparing the lightweight stitched shoe midsole nonwoven fabric according to any one of claims 1-3, characterized in that, include: High-strength DTY yarn (40wt%-60wt%) and high-strength FDY fiber (60wt%-40wt%) are mixed, opened, combed, and laid into a web to obtain a fiber web. The web is then stitched twice to obtain a greige fabric. The resulting greige fabric is then impregnated with acrylic emulsion and set at high temperature.

6. The method for preparing the thin and light stitched shoe midsole nonwoven fabric according to claim 5, characterized in that, In the sewing process, the stitch length is 4-8 stitches / cm and the thread tension is 15-35cN.

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