Method of manufacturing an athletic shoe and athletic shoe

Abstract

This invention relates to the field of athletic shoe manufacturing technology, and more particularly to a method for manufacturing athletic shoes, comprising the following steps: S1, preparing an intermediate support layer: using thermoplastic polyurethane elastomer to injection mold an intermediate support layer with a hollowed-out mesh structure; S2, molding a lower abrasion-resistant layer: placing the intermediate support layer in a mold cavity and molding the lower abrasion-resistant layer through a low-pressure injection molding foaming process; S3, molding an upper flexible layer: placing the intermediate support layer in a mold cavity and molding the upper flexible layer through a low-pressure injection molding foaming process; S4, preparing the upper: using a 3D flyknit process to weave an upper with a three-dimensional warp and weft structure; S5, assembly: pressing the upper and sole together with a hot melt adhesive film at 130℃-135℃ for 30 seconds, the hot melt adhesive film having a melting point of 110℃-120℃. This method solves the technical problems of existing athletic shoe manufacturing processes, such as a relatively simple sole structure, insufficient breathability and fit of the upper, and poor fabrication quality.

Description

Technical Field

[0001] This invention relates to the field of athletic shoe manufacturing technology, and more particularly to a method for manufacturing athletic shoes and athletic shoes. Background Technology

[0002] Currently, sports have become an important part of daily life, and the performance requirements for sports shoes are increasing. Traditional sports shoe manufacturing methods have limitations in many aspects and are difficult to meet the diverse needs of modern sports. A sports shoe sole with good anti-slip effect can be found in Chinese Patent Publication No. CN114947293A. Its structure includes a sole and a subsole, with the subsole bonded to the sole. The sole also has anti-slip blocks, several of which are bonded to the side and underside of the sole. The sole uses natural rubber to ensure the softness and elasticity required for sports shoes. The subsole uses PHYLON material to ensure the lightweight and elasticity required for sports shoes, and also has a shock-absorbing effect. The anti-slip blocks on the sole are made of hard rubber, effectively solving the problem of the sole's lack of wear resistance and making the sole slip-resistant.

[0003] In terms of sole structure, common athletic shoes often have a relatively simple sole design, failing to simultaneously provide support, durability, and flexibility. For example, some athletic shoes use only one material for their soles, resulting in either insufficient support, making it difficult to provide stable support during exercise and leading to foot fatigue and injury; poor durability, causing the sole to wear down easily after frequent use, affecting its lifespan; or poor flexibility, making the athlete's footwork less agile and reducing the overall athletic experience.

[0004] In terms of upper manufacturing, traditional processes often struggle to achieve good breathability and a good fit. Furthermore, existing athletic shoe assembly methods often use adhesives with poor environmental friendliness, and these adhesives are prone to coming unglued over long-term use, affecting the overall quality and durability of the shoes. Summary of the Invention

[0005] Therefore, in view of the above problems, the present invention proposes a method for manufacturing sports shoes, which solves the technical problems of the existing sports shoe manufacturing process, such as the relatively simple sole structure, insufficient breathability and fit of the upper, and poor quality of the manufacturing process.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A method for manufacturing athletic shoes includes the following steps:

[0008] S1. Preparation of intermediate support layer: The intermediate support layer with a hollow grid structure is formed by injection molding of thermoplastic polyurethane elastomer, with a grid density of 6-12 grids / cm².

[0009] S2. Molding the lower wear-resistant layer: The intermediate support layer is placed in the mold cavity, and the lower wear-resistant layer is formed by low-pressure injection foaming process. EVA / rubber blended foaming material is used, with a hardness of 65±10 ShoreC and an injection temperature of 160℃-175℃.

[0010] S3. Molding the upper flexible layer: The intermediate support layer with the lower wear-resistant layer obtained in step S2 is placed in the mold cavity, and the upper flexible layer is formed by low-pressure injection foaming process. Supercritical fluid foamed TPU material with a density of 0.18g / cm³-0.22g / cm³ and an injection temperature of 145℃-155℃ is used to form the shoe sole.

[0011] S4. Upper manufacturing: The upper is woven with a three-dimensional warp and weft structure using 3D flyknit technology, with a knitting density of 28-32 stitches / inch, forming breathable pores with a diameter of 1.5mm-2.0mm;

[0012] S5. Assembly: Press the upper and sole together with a hot melt adhesive film at 130℃-135℃ for 30 seconds. The melting point of the hot melt adhesive film is 110℃-120℃.

[0013] Furthermore, the hollowed-out mesh structure of the intermediate support layer is a hexagonal structure with a side length of 2mm-3mm and a wall thickness of 0.8mm-1.2mm. The mesh is filled with nano-sized silicone particles to enhance the resilience and fatigue resistance of the intermediate support layer.

[0014] Furthermore, the surface of the lower wear-resistant layer has anti-slip textures with a depth of 0.3mm-0.5mm.

[0015] Furthermore, the upper flexible layer has a foaming ratio of 4.5 to 5.2 times and a resilience of ≥65%. The upper flexible layer contains microcapsule phase change material, which can absorb or release heat according to temperature changes and regulate the temperature inside the shoe.

[0016] Furthermore, the upper flexible layer controls the pore structure by adjusting the ratio of CO2 / N2 mixed gas, with a pore diameter of 10μm-50μm and a pore density of 10. 5 pcs / cm³-10 7 The volume ratio of CO2 / N2 mixed gas is 1:1-3:1.

[0017] Furthermore, the weaving process of the shoe upper includes:

[0018] Double-feed weaving is performed using 400D nylon monofilament and 30D spandex covered yarn;

[0019] An elastic contraction zone is set in the arch area, with a contraction rate of 8%-12%;

[0020] The toe area features a double-layer reinforced structure, with a high-strength polyester fiber inner layer and a soft cotton material outer layer, ensuring both strength and improved comfort.

[0021] Furthermore, the lower wear-resistant layer is held at a pressure of 8MPa-10MPa for 15-20 seconds to ensure that the material fully fills the mold and reduces internal stress.

[0022] The upper flexible layer has a holding pressure of 5MPa-7MPa and a holding time of 10-15 seconds. Vibration injection molding technology is also used to reduce bubble generation and improve the uniformity of material density.

[0023] Furthermore, the shoe upper undergoes the following treatment after weaving:

[0024] Heat setting at 110℃-130℃ for 100-120 seconds to fix the shape of the shoe upper and prevent deformation;

[0025] The nano-level hydrophobic coating has a contact angle greater than 150°, giving the shoe upper superhydrophobic properties and effectively waterproofing it;

[0026] The antibacterial agent impregnation treatment has an antibacterial rate of ≥99%, and the antibacterial agent is a natural plant extract, which is safe and harmless;

[0027] UV protection treatment, UPF value ≥50+, effectively blocks UV damage.

[0028] Furthermore, the nanoscale hydrophobic coating spraying includes the following steps:

[0029] For the pre-treatment of the shoe upper, the woven shoe upper is cleaned with ultrasonic waves at a frequency of 40kHz-60kHz for 5-10 minutes. Then, the shoe upper is rinsed with deionized water and dried at a temperature of 60℃-80℃ for 20-30 minutes.

[0030] For the preparation of the hydrophobic solution, nano-silica particles with a particle size of 20nm-50nm were selected as the main hydrophobic component and added to an organic solvent. The organic solvent was a mixture of ethanol and acetone, with a volume ratio of ethanol to acetone of 3:1-5:1. The mixture was stirred using a magnetic stirrer at a speed of 300-500 rpm for 30-60 minutes to ensure uniform dispersion of the nano-silica particles in the organic solvent. A hydrophobic agent, perfluorooctyltriethoxysilane, was then added to the uniformly dispersed solution at a rate of 5%-10% of the mass of the nano-silica particles. Stirring was continued at a speed of 600-800 rpm for 60-90 minutes to allow the hydrophobic agent to fully react with the nano-silica particles and form a stable nano-hydrophobic coating solution.

[0031] For the spraying operation, the air pressure of the spray gun is 0.2MPa-0.3MPa, the spraying distance is 20cm-30cm, the spraying angle is perpendicular to the shoe surface, and multiple thin sprays are used. The thickness of each spray is controlled at 1μm-2μm, and a total of 3-5 sprays are performed to make the total coating thickness of the shoe surface reach 3μm-10μm.

[0032] For coating curing, place the shoe upper in a curing oven at a temperature of 100℃-120℃ for curing for 30-60 minutes, and then allow the shoe upper to cool naturally to room temperature.

[0033] Furthermore, the thickness ratio of each layer of the sole is as follows:

[0034] Lower wear-resistant layer: 25%-30%;

[0035] Intermediate support layer: 20%-25%;

[0036] Upper flexible layer: 45%-55%;

[0037] Furthermore, the sole features a gradient density design, with the density gradually decreasing from the heel to the toe.

[0038] A sports shoe based on the same inventive concept is formed using a method for manufacturing sports shoes. It includes a sole and an upper bonded to the sole. The sole includes, from bottom to top, a lower abrasion-resistant layer, a middle support layer, and an upper flexible layer. The middle support layer has a hollowed-out mesh structure. The hollowed-out mesh structure is a hexagonal structure with a side length of 2mm-3mm and a wall thickness of 0.8mm-1.2mm. The mesh is filled with nano-sized silicone particles. The upper flexible layer is embedded with microcapsule phase change material. A skeleton support structure is provided on the peripheral side of the sole connecting the lower abrasion-resistant layer and the upper flexible layer.

[0039] By adopting the aforementioned technical solution, the beneficial effects of the present invention are:

[0040] 1. This method manufactures athletic shoes by combining a multi-layered sole with a specially crafted upper. The middle support layer provides structural support; the lower abrasion-resistant layer gives the sole excellent wear resistance, extending the shoe's lifespan; and the upper flexible layer provides a comfortable feel and good cushioning. The 3D flyknit upper offers excellent breathability, keeping feet dry. The hot-melt adhesive film assembly method is environmentally friendly and provides a strong bond, improving the overall quality and durability of the shoe and offering athletes a better athletic experience.

[0041] 2. The intermediate support layer adopts a hexagonal hollow mesh structure, which has high stability and mechanical properties, and can evenly distribute pressure in all directions. The reasonable design of side length and wall thickness ensures the strength and lightweight of the support layer. The mesh is filled with nano-sized silicone particles, which have good elasticity and fatigue resistance, enhancing the resilience of the support layer, allowing athletes to feel more stable support during exercise and reducing foot fatigue.

[0042] 3. The wavy anti-slip pattern on the lower abrasion layer increases the friction between the sole and the ground. The design of the depth and spacing of the treads ensures that the anti-slip pattern effectively grips the ground without compromising the abrasion resistance and flexibility of the sole due to excessive depth or density. During exercise, especially on wet or slippery surfaces, it effectively prevents slipping and improves safety.

[0043] 4. The upper flexible layer has a high foaming ratio, making the material softer and providing excellent cushioning and shock absorption. A rebound rate of ≥65% ensures the sole quickly returns to its original shape after being subjected to pressure, reducing energy loss. The microcapsule phase change material inside the flexible layer absorbs or releases heat according to temperature changes. During exercise, the foot generates heat, and the microcapsule phase change material absorbs this heat to maintain a comfortable temperature inside the shoe. When the ambient temperature is low, the microcapsule phase change material releases heat to keep the feet warm, improving wearing comfort.

[0044] 5. By adjusting the ratio of CO2 / N2 mixed gas, the cell structure of the upper flexible layer can be controlled. Appropriate cell diameter and density can optimize material performance. Smaller cell diameter and higher cell density can improve the material's strength and cushioning performance, while also making the material more uniform. The use of CO2 / N2 mixed gas can also reduce the defects that may result from using only one gas, improve foaming quality, and further enhance the performance of the upper flexible layer.

[0045] 6. The upper is constructed using a double-feed weave of 400D nylon monofilament and 30D spandex-covered yarn. The nylon monofilament provides strength, while the spandex-covered yarn increases elasticity, resulting in an upper that is both sturdy and resilient. The elastic compression zone in the arch area better conforms to the arch, providing additional support and comfort; the optimized compression rate ensures a snug fit. The double-layered reinforced structure at the toe area features an inner layer of high-strength polyester fiber to enhance abrasion resistance and impact resistance, while the outer layer of soft cotton material improves wearing comfort and reduces friction on the feet.

[0046] 7. The lower abrasion-resistant layer uses higher holding pressure and a longer holding time to ensure that the material fully fills the mold, reducing internal stress and improving the density and abrasion resistance of the sole. The upper flexible layer uses lower holding pressure and a shorter holding time, combined with vibration injection molding technology, to reduce bubble formation, improve material density uniformity, and make the upper flexible layer more stable and provide better cushioning.

[0047] 8. Heat setting at 110℃-130℃ fixes the shape of the shoe upper, preventing deformation during subsequent use and processing, ensuring the shoe's aesthetics and fit. A nano-level hydrophobic coating gives the upper superhydrophobic properties with a contact angle greater than 150°, effectively preventing rain and water penetration and keeping feet dry. Antibacterial impregnation treatment with an antibacterial rate ≥99% uses natural plant extracts as antibacterial agents, ensuring safety and harmlessness, inhibiting bacterial growth, and preventing foot diseases. UV protection treatment achieves a UPF value ≥50+, effectively blocking UV damage and protecting foot skin health.

[0048] 9. In the pretreatment of the shoe upper, ultrasonic cleaning can thoroughly remove impurities and oil stains from the surface, providing a good foundation for subsequent coating adhesion. Drying removes moisture to prevent affecting coating quality. During the preparation of the hydrophobic solution, the appropriate particle size of nano-silica and the ratio of organic solvent are selected, and the particles are evenly dispersed by magnetic stirring before the hydrophobic agent is added to fully react and form a stable coating solution. During the spraying operation, suitable spray gun air pressure, spray distance and angle, and multiple thin sprays ensure uniform coating adhesion to the shoe upper. The coating curing treatment forms a dense structure, enhancing hydrophobic properties and durability; natural cooling to room temperature prevents coating cracking due to sudden temperature changes.

[0049] 10. The design of the thickness ratio of each layer of the sole rationally allocates the functions of different layers. The lower abrasion-resistant layer accounts for 25%-30%, ensuring sufficient abrasion resistance; the middle support layer accounts for 20%-25%, providing stable support; and the upper flexible layer accounts for 45%-55%, providing good cushioning and comfort. The gradient density design gradually decreases from heel to toe, conforming to ergonomic principles. The heel area needs to withstand greater pressure, and the higher density provides better support and cushioning; the toe area needs more flexibility, and the lower density increases flexibility, allowing athletes to move more freely during exercise.

[0050] 11. Sports shoes manufactured using the above-described method have good support, wear resistance, flexibility, breathability, slip resistance, comfort, antibacterial properties, waterproofness, and UV protection, which can meet the needs of athletes in different sports scenarios and improve athletic performance and wearing experience. Attached Figure Description

[0051] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0052] Figure 2 This is a schematic diagram of the shoe sole structure.

[0053] Figure 3 This is a cross-sectional view of the shoe sole.

[0054] Figure 4 This is a schematic diagram of the bottom structure of the shoe sole.

[0055] Figure label:

[0056] 1. Outsole; 11. Lower abrasion-resistant layer; 12. Middle support layer; 13. Upper flexible layer; 121. Hollowed-out mesh structure; 122. Nanoscale silicone particles; 131. Microcapsule phase change material; 14. Skeleton support structure; 2. Upper. Detailed Implementation

[0057] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments.

[0058] This embodiment provides a method for manufacturing athletic shoes, including the following steps:

[0059] S1. Preparation of intermediate support layer: The intermediate support layer 12 with a hollow grid structure 121 is formed by injection molding of thermoplastic polyurethane elastomer, with a grid density of 6-12 grids / cm².

[0060] S2. Molding the lower wear-resistant layer: The intermediate support layer 12 is placed in the mold cavity, and the lower wear-resistant layer 11 is formed by low-pressure injection foaming process. EVA / rubber blended foaming material is used, with a hardness of 65±10 ShoreC and an injection temperature of 160℃-175℃.

[0061] S3. Molding the upper flexible layer: The intermediate support layer 12 with the lower wear-resistant layer 11 obtained in step S2 is placed in the mold cavity, and the upper flexible layer 13 is formed by low-pressure injection foaming process. Supercritical fluid foaming TPU material with a density of 0.18g / cm³-0.22g / cm³ and an injection temperature of 145℃-155℃ is used to form the shoe sole 1.

[0062] S4. Upper preparation: The upper 2 is woven with a three-dimensional warp and weft structure using 3D flyknit technology, with a knitting density of 28 stitches / inch to 32 stitches / inch, forming breathable pores with a diameter of 1.5mm to 2.0mm;

[0063] S5. Assembly: Press the upper 2 and the sole 1 together with a hot melt adhesive film at 130℃-135℃ for 30 seconds. The melting point of the hot melt adhesive film is 110℃-120℃.

[0064] The hollowed-out mesh structure 121 of the intermediate support layer 12 is hexagonal, with a side length of 2mm-3mm and a wall thickness of 0.8mm-1.2mm. The mesh is filled with nano-sized silicone particles 122 to enhance the resilience and fatigue resistance of the intermediate support layer 12. The nano-sized silicone particles 122 are made of nano-silicone, such as Dow Corning's SY-330 nano-silicone. The hexagonal mesh structure has good mechanical stability and can evenly distribute the pressure applied to the feet during exercise. The filling of nano-sized silicone particles 122 allows the intermediate support layer 12 to quickly return to its original shape after being subjected to pressure, greatly improving resilience and reducing fatigue during exercise.

[0065] The lower wear-resistant layer 11 has anti-slip textures with a depth of 0.3mm-0.5mm on its surface. It uses an EVA / rubber blend foam material, where the EVA is Hanwha Total's LH820 model from South Korea, and the rubber is styrene-butadiene rubber (SBR), blended in a 7:3 ratio. This blend material combines the lightweight properties of EVA with the wear resistance of rubber. The hardness is 65 Shore C, and the injection molding temperature is set at 170℃. The lower wear-resistant layer 11 also has anti-slip textures with a depth of 0.4mm on its surface (not marked in the figure).

[0066] The upper flexible layer 13 has a foaming ratio of 4.5 to 5.2 times and a resilience of ≥65%. The upper flexible layer 13 contains microcapsule phase change material 131, which can absorb or release heat according to temperature changes to regulate the temperature inside the shoe. The upper flexible layer 13 controls the cell structure by adjusting the ratio of CO2 / N2 mixed gas, with a cell diameter of 10 μm to 50 μm and a cell density of 10. 5 pcs / cm³-10 7 The volume ratio of CO2 / N2 mixed gas is 1:1-3:1.

[0067] Specifically, supercritical fluid foamed TPU material is used, specifically Lubrizol's ESTANE58245 model. This TPU forms a uniform and fine cell structure after supercritical fluid foaming. The density is 0.20 g / cm³, and the injection molding temperature is 150℃. The upper flexible layer 13 has a foaming ratio of 4.8 times and a resilience of ≥68%. The upper flexible layer 13 contains microcapsule phase change material 131, which is LK-PCM101 microcapsule paraffin produced by Luco Biotechnology. Its phase change temperature range is between 25℃ and 35℃, allowing it to absorb or release heat according to temperature changes and regulate the temperature inside the shoe. The cell structure is controlled by adjusting the ratio of CO2 / N2 mixed gas, resulting in a cell diameter of 30 μm and a cell density of 5 × 10⁻⁶. 6 The volume ratio of CO2 / N2 mixed gas is 2:1. Suitable foaming ratio and resilience give the upper flexible layer 13 excellent cushioning performance, effectively reducing the impact on the feet during exercise. The addition of microcapsule phase change material 131 helps maintain a relatively stable temperature inside the shoe, improving wearing comfort. The finely controlled pore structure further optimizes the material's performance.

[0068] The thickness ratio of each layer of the sole 1 is as follows:

[0069] Lower wear-resistant layer 11: 25%-30%;

[0070] Intermediate support layer 12: 20%-25%;

[0071] Upper flexible layer 13: 45%-55%;

[0072] Furthermore, the sole 1 adopts a gradient density design, with the density gradually decreasing from the heel to the toe.

[0073] The lower wear-resistant layer 11 has a holding pressure of 8MPa-10MPa and a holding time of 15-20 seconds to ensure that the material fully fills the mold and reduces internal stress; the upper flexible layer 13 has a holding pressure of 5MPa-7MPa and a holding time of 10-15 seconds. Vibration injection molding technology is used to reduce the generation of air bubbles and improve the uniformity of material density.

[0074] The weaving process of the shoe upper 2 includes:

[0075] Double-feed weaving is performed using 400D nylon monofilament and 30D spandex covered yarn;

[0076] An elastic contraction zone is set in the arch area, with a contraction rate of 8%-12%;

[0077] The toe area features a double-layer reinforced structure, with a high-strength polyester fiber inner layer and a soft cotton material outer layer, ensuring both strength and improved comfort.

[0078] The nylon monofilament is LP-400D manufactured by Lipeng Enterprise Co., Ltd., and the spandex covering yarn is XS-30D manufactured by Hyosung Group. The upper 2 is woven using a 3D flyknit process with a three-dimensional warp and weft structure, with a knit density of 30 stitches / inch, creating 1.8mm diameter breathable pores. An elastic compression zone is incorporated in the arch area, with a shrinkage rate of 10%. The toe area features a double-layer reinforced structure: an inner layer of high-strength polyester fiber, using DuPont's Coolmax polyester fiber, and an outer layer of soft cotton material, using long-staple cotton. The 3D flyknit process and appropriate knit density give the upper 2 excellent breathability and fit. The elastic compression zone in the arch area better adapts to the shape of the arch, providing comfortable support. The double-layer reinforced structure in the toe area ensures both strength and improved wearing comfort.

[0079] The shoe upper 2 undergoes the following treatment after weaving:

[0080] Heat setting at 110℃-130℃ for 100-120 seconds to fix the shape of the shoe upper and prevent deformation;

[0081] The nano-level hydrophobic coating spraying, with a contact angle greater than 150°, gives the shoe upper 2 super hydrophobic properties, effectively waterproofing it;

[0082] The antibacterial agent impregnation treatment has an antibacterial rate of ≥99%, and the antibacterial agent is a natural plant extract, which is safe and harmless;

[0083] UV protection treatment, UPF value ≥50+, effectively blocks UV damage.

[0084] Furthermore, the nanoscale hydrophobic coating spraying includes the following steps:

[0085] For the pretreatment of the shoe upper, the completed woven shoe upper 2 is cleaned with ultrasonic waves at a frequency of 40kHz-60kHz for 5-10 minutes. Then, the shoe upper 2 is rinsed with deionized water and dried at a temperature of 60℃-80℃ for 20-30 minutes.

[0086] For the preparation of the hydrophobic solution, nano-silica particles with a particle size of 20nm-50nm were selected as the main hydrophobic component and added to an organic solvent. The organic solvent was a mixture of ethanol and acetone, with a volume ratio of ethanol to acetone of 3:1-5:1. The mixture was stirred using a magnetic stirrer at a speed of 300-500 rpm for 30-60 minutes to ensure uniform dispersion of the nano-silica particles in the organic solvent. A hydrophobic agent, perfluorooctyltriethoxysilane, was then added to the uniformly dispersed solution at a rate of 5%-10% of the mass of the nano-silica particles. Stirring was continued at a speed of 600-800 rpm for 60-90 minutes to allow the hydrophobic agent to fully react with the nano-silica particles and form a stable nano-hydrophobic coating solution.

[0087] For the spraying operation, the air pressure of the spray gun is 0.2MPa-0.3MPa, the spraying distance is 20cm-30cm, the spraying angle is perpendicular to the surface of the shoe upper 2, and multiple thin sprays are used. The coating thickness of each spray is controlled at 1μm-2μm, and a total of 3-5 sprays are performed to make the total coating thickness of the shoe upper 2 surface reach 3μm-10μm.

[0088] For coating curing, place the shoe upper 2 in a curing oven at a temperature of 100℃-120℃ for curing treatment for 30-60 minutes, and then allow the shoe upper 2 to cool naturally to room temperature.

[0089] The coating curing stage includes:

[0090] Heating Phase: The heating process needs to be slow and uniform to avoid stress buildup within the coating due to a rapid temperature increase, which could affect the adhesion between the coating and the shoe upper 2, as well as the coating's own performance. The initial temperature should be set between 50℃ and 60℃, and then increased at a rate of 2℃ to 3℃ per minute to allow the shoe upper 2 and the coating to gradually adapt to the temperature change. Furthermore, the airflow of the ventilation system must be properly controlled to prevent the accumulation of volatile substances in the furnace, which could lead to safety hazards or affect the coating quality.

[0091] Isothermal Stage: When the oven temperature reaches the preset curing temperature (100℃-120℃), the temperature is maintained stable. At this time, the chemical reaction in the coating begins to accelerate, and the nano-silica particles and the hydrophobic agent react further to form a more stable and dense hydrophobic structure. The isothermal curing time is one of the key factors ensuring coating performance. Depending on the characteristics and thickness of the coating material, the shoe upper 2 generally needs to be maintained at the target temperature for 30-60 minutes. To ensure uniform curing of the coating on all parts of the shoe upper 2, a hot air circulation system is typically used in the curing oven. Hot air circulates continuously within the oven, evenly distributing heat to every corner of the shoe upper 2, preventing localized overheating or underheating.

[0092] Cooling Stage: After the constant temperature curing stage, the shoe upper 2 needs to be cooled down. Generally, natural cooling is used first, allowing the shoe upper 2 to cool slowly in the oven for a period of time, gradually stabilizing the internal structure of the coating. This time can be controlled to approximately 10-15 minutes, depending on the actual situation. Afterwards, the cooling fan of the curing oven can be turned on or cooling air can be introduced to control the cooling rate and achieve reasonable cooling control, avoiding uneven coating shrinkage and cracking caused by excessively rapid cooling.

[0093] The above numerical range can be selected according to actual needs.

[0094] refer to Figures 1 to 4 A sports shoe manufactured based on the above method includes a sole 1 and an upper 2 bonded to the sole 1. The sole 1 includes a lower wear-resistant layer 11, a middle support layer 12, and an upper flexible layer 13 from bottom to top. The middle support layer 12 has a hollow mesh structure 121. The hollow mesh structure 121 is a hexagonal structure with a side length of 2mm-3mm and a wall thickness of 0.8mm-1.2mm. The mesh is filled with nano-sized silicone particles 122. The upper flexible layer 13 is embedded with microcapsule phase change material 131. A skeleton support structure 14 is provided on the peripheral side of the sole 1 between the lower wear-resistant layer 11 and the upper flexible layer 13.

[0095] These athletic shoes offer the following benefits:

[0096] 1. The hexagonal hollow mesh structure 121 of the intermediate support layer 12 has high mechanical stability and can evenly distribute the pressure applied to the feet during movement in all directions, effectively preventing fatigue and injury to the feet caused by uneven force during movement.

[0097] The hexagonal mesh ensures the strength of the middle support layer 12 while maintaining lightweight design, allowing the athletic shoe to provide stable support without adding too much burden.

[0098] The nanoscale silicone particles 122 filling the mesh have good elasticity and fatigue resistance, which can significantly enhance the resilience of the intermediate support layer 12.

[0099] During exercise, these nano-sized silicone particles 122 can effectively absorb and disperse impact force, reducing the reaction force on the feet, thereby improving exercise comfort and stability.

[0100] 2. The lower abrasion layer 11, made of EVA / rubber blended foam material, combines the lightweight of EVA with the abrasion resistance of rubber. Its surface design features a wave-shaped anti-slip pattern that further increases the friction between the sole 1 and the ground, effectively preventing slips and improving sports safety. It also extends the service life of the sole 1, maintaining good abrasion resistance even after frequent use.

[0101] 3. The upper flexible layer 13, made of supercritical fluid foamed TPU material, has a high foaming ratio and resilience, making the material softer and more elastic. It can effectively reduce the impact on the feet during exercise, provide good cushioning, and protect the foot joints from injury.

[0102] The microcapsule phase change material 131 embedded inside the upper flexible layer 13 can absorb or release heat according to temperature changes, regulating the temperature inside the shoe. During exercise, the heat generated by the feet is absorbed by the microcapsule phase change material 131, keeping the temperature inside the shoe suitable; when the ambient temperature is low, the microcapsule phase change material 131 releases heat to keep the feet warm. This intelligent adjustment function significantly improves wearing comfort.

[0103] 4. The upper, woven using 3D flyknit technology, features a three-dimensional warp and weft structure with a moderate weaving density, creating numerous breathable pores with a diameter of 1.5mm-2.0mm. These pores effectively promote air circulation between the inside and outside of the shoe, keeping feet dry and preventing discomfort caused by stuffiness and dampness.

[0104] Upper 2 features an elastic compression zone in the arch area, which better conforms to the shape of the arch, providing additional support and comfort. This allows Upper 2 to maintain good breathability while also closely conforming to the foot, improving stability and flexibility during exercise.

[0105] 5. The upper 2 and the sole 1 are assembled under specific conditions using a hot melt adhesive film. This method is not only environmentally friendly and pollution-free, but also provides a high degree of bonding strength, effectively preventing the shoes from coming apart. This greatly improves the overall quality and durability of the shoes, extending their service life.

[0106] The skeletal support structure 14, which connects the lower abrasion-resistant layer 11 and the upper flexible layer 13 on the side of the sole 1, further enhances the stability and durability of the sole 1. This allows the shoe to maintain its structural integrity and resist deformation or damage even when subjected to complex movement postures.

[0107] 6. The sole features a gradient density design across its layers, with density gradually decreasing from the heel to the toe. This ergonomic design is based on the principle that the heel area needs to withstand greater pressure, and the higher density provides better support and cushioning; while the toe area requires more flexible movement, and the lower density increases agility. This comprehensive performance enhancement allows the shoe to adapt to the needs of different sports scenarios, improving athletic performance and wearing experience.

[0108] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. A method for manufacturing athletic shoes, characterized in that, Includes the following steps: S1. Preparation of intermediate support layer: The intermediate support layer (12) with a hollow grid structure (121) is formed by injection molding of thermoplastic polyurethane elastomer, with a grid density of 6-12 grids / cm². S2, forming the lower wear-resistant layer: the intermediate support layer (12) is placed in the mold cavity, and the lower wear-resistant layer (11) is formed by low-pressure injection foaming process. EVA / rubber blended foaming material is used, with a hardness of 65±10 Shore C and an injection temperature of 160℃-175℃. S3. Molding the upper flexible layer: The intermediate support layer (12) with the lower wear-resistant layer (11) obtained in step S2 is placed in the mold cavity, and the upper flexible layer (13) is formed by low-pressure injection foaming process. Supercritical fluid foaming TPU material with a density of 0.18g / cm³-0.22g / cm³ and an injection temperature of 145℃-155℃ is used to form the shoe sole (1). S4. Upper preparation: The upper is made of 3D flyknitting technology with a three-dimensional warp and weft structure (2), with a knitting density of 28 stitches / inch to 32 stitches / inch, forming breathable pores with a diameter of 1.5mm to 2.0mm; S5. Assembly: Press the upper (2) and sole (1) together with a hot melt adhesive film at 130℃-135℃ for 30 seconds. The melting point of the hot melt adhesive film is 110℃-120℃.

2. The method for manufacturing sports shoes according to claim 1, characterized in that, The hollow grid structure (121) of the intermediate support layer (12) is a hexagonal structure with a side length of 2mm-3mm and a wall thickness of 0.8mm-1.2mm. The grid is filled with nano-sized silicone particles (122) to enhance the resilience and fatigue resistance of the intermediate support layer (12).

3. The method for manufacturing sports shoes according to claim 1, characterized in that, The surface of the lower wear-resistant layer (11) has anti-slip textures with a depth of 0.3mm-0.5mm.

4. The method for manufacturing sports shoes according to claim 1, characterized in that, The upper flexible layer (13) has a foaming ratio of 4.5 to 5.2 times and a resilience of ≥65%. The upper flexible layer (13) contains microcapsule phase change material (131), which can absorb or release heat according to temperature changes and regulate the temperature inside the shoe.

5. A method for manufacturing athletic shoes according to claim 4, characterized in that, The upper flexible layer (13) controls the pore structure by adjusting the ratio of CO2 / N2 mixed gas, with a pore diameter of 10μm-50μm and a pore density of 10. 5 pcs / cm³-10 7 The volume ratio of CO2 / N2 mixed gas is 1:1-3:

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6. The method for manufacturing athletic shoes according to claim 1, characterized in that, The weaving process of the shoe upper includes: Double-feed weaving is performed using 400D nylon monofilament and 30D spandex covered yarn; An elastic contraction zone is set in the arch area, with a contraction rate of 8%-12%; The toe area features a double-layer reinforced structure, with a high-strength polyester fiber inner layer and a soft cotton material outer layer.

7. A method for manufacturing athletic shoes according to claim 1, characterized in that, The lower wear-resistant layer (11) has a holding pressure of 8MPa-10MPa and a holding time of 15-20 seconds to ensure that the material fully fills the mold and reduces internal stress. The upper flexible layer (13) has a holding pressure of 5MPa-7MPa and a holding time of 10-15 seconds. At the same time, vibration injection molding technology is used to reduce the generation of bubbles and improve the uniformity of material density.

8. A method for manufacturing athletic shoes according to claim 1, characterized in that, The upper (2) undergoes the following treatment after weaving: Heat setting at 110℃-130℃ for 100-120 seconds to fix the shape of the shoe upper (2) and prevent deformation; The nano-level hydrophobic coating is sprayed with a contact angle greater than 150°, giving the shoe surface (2) superhydrophobic properties; The antibacterial agent is impregnated, resulting in an antibacterial rate of ≥99%, and the antibacterial agent is a natural plant extract. UV protection treatment, UPF value ≥50+, blocks UV damage.

9. A method for manufacturing athletic shoes according to claim 8, characterized in that, The nanoscale hydrophobic coating application includes the following steps: For shoe upper pretreatment, the finished woven shoe upper (2) is cleaned by ultrasonic cleaning. The ultrasonic frequency is set to 40kHz-60kHz and the cleaning time is 5 minutes-10 minutes. Then the shoe upper (2) is rinsed with deionized water and then dried. The drying temperature is 60℃-80℃ and the drying time is 20 minutes-30 minutes. For the preparation of the hydrophobic solution, nano-silica particles with a particle size of 20nm-50nm were selected as the main hydrophobic component and added to an organic solvent. The organic solvent was a mixture of ethanol and acetone, with a volume ratio of ethanol to acetone of 3:1-5:

1. The mixture was stirred using a magnetic stirrer at a speed of 300-500 rpm for 30-60 minutes to ensure uniform dispersion of the nano-silica particles in the organic solvent. A hydrophobic agent, perfluorooctyltriethoxysilane, was then added to the uniformly dispersed solution at a rate of 5%-10% of the mass of the nano-silica particles. Stirring was continued at a speed of 600-800 rpm for 60-90 minutes to allow the hydrophobic agent to fully react with the nano-silica particles and form a stable nano-hydrophobic coating solution. For the spraying operation, the air pressure of the spray gun is 0.2MPa-0.3MPa, the spraying distance is 20cm-30cm, the spraying angle is perpendicular to the surface of the shoe (2), and multiple thin sprayings are used. The coating thickness of each spray is controlled at 1μm-2μm, and a total of 3-5 sprayings are carried out to make the total coating thickness of the shoe surface (2) reach 3μm-10μm. For coating curing, the shoe upper (2) is placed in a curing oven at a temperature of 100℃-120℃ for curing treatment for 30 minutes-60 minutes, and then the shoe upper (2) is allowed to cool naturally to room temperature.

10. A type of athletic shoe, characterized in that, The method of manufacturing sports shoes according to any one of claims 1 to 9 is used to form a sole (1) and an upper (2) bonded to the sole (1). The sole (1) includes a lower wear-resistant layer (11), a middle support layer (12) and an upper flexible layer (13) from bottom to top. The middle support layer (12) has a hollow mesh structure (121). The hollow mesh structure (121) is a hexagonal structure with a side length of 2mm-3mm and a wall thickness of 0.8mm-1.2mm. The mesh is filled with nano-sized silicone particles (122). The upper flexible layer (13) is embedded with microcapsule phase change material (131). A skeleton support structure (14) is provided on the periphery of the sole (1) between the lower wear-resistant layer (11) and the upper flexible layer (13).

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