A method of integrated printing of a multi-material interlocking structural sole

Abstract

The application discloses a kind of integrally formed printing methods of multi-material interlocking structure shoe sole, comprising the following steps: designing shoe sole three-dimensional model, slice processing, according to slice file, first print shoe sole, first print shoe outsole bottom layer, adopt tenacity wear-resistant material, print filling rate 20%-50%, interlocking structure base is printed in shoe outsole specified area, simultaneously switch to support plate material and print support plate structure, support plate thickness 0.5-2mm, when printing shoe midsole, control shoe midsole thickness is 30-40mm, print filling rate is 30%-50%, and with the combination area of support plate, and with the combination area of shoe outsole realizes crosslinking interlocking.The application discloses a kind of integrally formed printing methods of multi-material interlocking structure shoe sole, multi-material interlocking structure makes the combination strength of shoe sole each component improve, is tested by tensile test, and the fracture strength of junction is good.Production efficiency is improved, need not mould, and production cost is reduced.

Description

Technical Field

[0001] This invention belongs to the field of 3D printing technology, and in particular relates to a method for integral molding and printing of a multi-material interlocking structure shoe sole. Background Technology

[0002] Current shoe sole manufacturing methods and processes: Traditional manufacturing methods mostly use molding, injection molding and other processes, which require the pre-made molds, and different materials are injected or molded separately before assembly.

[0003] High mold costs and long development cycles make it difficult to quickly respond to small-batch, personalized customization needs. Assembling multiple components results in insufficient strength at joints, easily leading to problems such as delamination and breakage.

[0004] Significant material waste and the inability to achieve precise material allocation and manufacture complex structures limit the overall performance of the shoe sole.

[0005] In view of this, the inventor of this case conducted in-depth research, which led to the creation of this case. Summary of the Invention

[0006] The purpose of this invention is to provide a one-piece molding printing method for a multi-material interlocking structure sole that can reduce production costs (reduce mold expenditure), improve the overall bonding strength of the sole, achieve precise allocation of multiple materials, and meet personalized customization needs.

[0007] To achieve the above objectives, the technical solution of the present invention is as follows:

[0008] A method for integral molding and printing a multi-material interlocking structure shoe sole includes the following steps:

[0009] Step S1: Design a three-dimensional model of the shoe sole, and determine the interlocking structure and interlocking area between the various components of the shoe sole. The shoe sole includes a midsole, a support plate, and an outsole. The support plate is located inside the midsole.

[0010] Step S2: Slice the designed shoe sole into pieces with a thickness of 0.1~0.26mm, and set the printing parameters for each component material;

[0011] Step S3: Material Preparation

[0012] Prepare the shoe midsole material, using a soft material with a diameter of 1.75mm or 2.85mm;

[0013] Prepare the support plate material, with a diameter of 1.75mm or 2.85mm;

[0014] Prepare the outsole material; the diameter of the outsole material should be 1.75mm or 2.85mm.

[0015] Step S4: Printing Platform Preparation

[0016] Clean the surface of the printing platform;

[0017] Step S5: Print according to the designed printing parameters. The multi-material printing process is as follows:

[0018] Step S5.1: Start the printer and preheat the printhead and platform:

[0019] The nozzle temperature for the soft material in the shoe midsole is controlled at 190-230℃, the nozzle temperature for the support plate material is controlled at 220-260℃, and the nozzle temperature for the outsole material is controlled at 230-270℃.

[0020] The platform temperature should be controlled between 50-100℃;

[0021] Step S5.2: According to the slicing parameters, first print the bottom layer of the shoe outsole using a tough and wear-resistant material with a printing fill rate of 20%-50%. Print the interlocking structure base in the designated area of ​​the shoe outsole. At the same time, switch to the support plate material to print the support plate structure. The support plate thickness is 0.5-2mm, and the fill rate of the support plate material is 80%-100%.

[0022] When printing the shoe midsole, the thickness of the shoe midsole is controlled to be 30~40mm, the printing fill rate is 30%-50%, and cross-linking and interlocking are achieved in the joint area with the support plate and the joint area with the outsole.

[0023] The sole is printed layer by layer until it is completed. During the printing process, each nozzle automatically switches materials according to the model area. After printing, a multi-material interlocking one-piece molded sole is obtained.

[0024] Step S6: Post-processing

[0025] After printing is complete, wait for the platform to cool to room temperature before removing the shoe sole.

[0026] Furthermore, in step S5.2, the printing process is controlled as follows:

[0027] Nozzle switching: Initiate early switching in an area 0.2mm outside the support plate boundary to ensure that the material overlaps at the junction with an overlap width of 0.15mm;

[0028] Flow control: The flow rate of the support plate material is increased to 105% in the interlocked zone until the melt is filled, and the flow rate is 100% in the non-interlocked zone;

[0029] Temperature control: After the support plate is printed, the printing platform is heated to diffuse the molecules at the interface between the shoe midsole material and the support plate.

[0030] Interlocking structure: When the shoe midsole material is printed, the melt is embedded in the groove of the interlocking area around the support plate and solidifies to form a mechanical anchor;

[0031] Forefoot area: The midsole has a 40% filling rate and a spiral filling structure;

[0032] Arch area: The thickness of the support plate has been increased from 1mm to 1.2mm;

[0033] Heel area: The midsole has a 30% fill rate and a honeycomb structure.

[0034] Furthermore, the interlocking structure includes a sawtooth interlocking structure for interlayer mating, a tenon-and-mortise interlocking structure for interlayer mating, or a spiral interlocking structure for interlayer stacking.

[0035] Furthermore, the support plate and the midsole of the shoe adopt a sawtooth interlocking structure; the outsole of the shoe and the midsole of the shoe adopt a tenon and mortise interlocking structure.

[0036] Furthermore, the support plate is a carbon fiber plate or a nylon plate, the midsole is a PEBA sole, and the outsole is a TPU sole.

[0037] Furthermore, the tooth depth of the sawtooth interlocking structure is 0.5 mm and the tooth pitch is 1.5 mm; the tenon-and-mortise structure is 0.7 mm wide and 0.3 mm high.

[0038] Furthermore, the outsole adopts a mesh structure with a fill rate of 50%.

[0039] By adopting the above technical solution, the one-piece molding printing method for a multi-material interlocking structure shoe sole of the present invention has the following beneficial effects: The multi-material interlocking structure improves the bonding strength of each component of the shoe sole, and tensile tests show good fracture strength at the joints. Production efficiency is improved; no molds are needed, and the process goes directly from digital model to product, shortening the development cycle by 50%-70%. The traditional process development cycle is about 4-6 weeks, while this process takes about 1-2 weeks. Small-batch personalized customization production can be achieved, with production efficiency 2-3 times higher than traditional processes. Cost savings are achieved by eliminating mold manufacturing costs; for small-batch production (50-100 pairs), costs are reduced by 40%-60%. Material utilization is improved, reducing waste; the traditional process material utilization rate is about 60%-70%, while this process can reach 85%-95%. Attached Figure Description

[0040] Figure 1 This is a schematic diagram of the shoe sole structure of the present invention;

[0041] Figure 2 This is a schematic diagram of the printing support state of the shoe sole according to the present invention;

[0042] Figure 3 This is a cross-sectional view of the sole of the shoe according to the present invention;

[0043] Figure 4 This is a cross-sectional and partially enlarged view of the sole of the shoe according to the present invention;

[0044] Figure 5 This is a schematic diagram of the sawtooth interlocking structure of the present invention.

[0045] Figure 6 This is a schematic diagram of the tenon-and-mortise interlocking structure of the present invention;

[0046] Figure 7 This is a schematic diagram of the spiral interlocking structure of the present invention.

[0047] In the picture:

[0048] Shoe midsole 01; support plate 02; perimeter 021; outsole 03; joint area 031; interlocking structure 04; serrated interlocking structure 05; tenon and mortise interlocking structure 06; spiral interlocking structure 07. Detailed Implementation

[0049] This invention discloses a method for integral molding and printing a multi-material interlocking structure shoe sole, comprising the following steps:

[0050] Step S1: As Figures 1-4 As shown, a three-dimensional model of the shoe sole is designed. The three-dimensional model of the shoe sole is designed using three-dimensional modeling software (such as Rhino, Blender, etc.). The interlocking structure 04 and interlocking area between the various components of the shoe sole (midsole 01, support plate 02, outsole 03) are determined. The shoe sole includes the midsole 01, support plate 02 and outsole 03. The support plate 02 is set inside the midsole 03.

[0051] Step S2: Slice the designed shoe sole, set the printing parameters for each component material, the slice thickness is 0.1~0.26mm, the optimal value is 0.15mm, the printing speed is different for different materials, the speed range is generally 60-200mm / s;

[0052] Step S3: Material Preparation

[0053] Prepare the midsole material, using a soft material with a diameter of 1.75mm or 2.85mm; 1.75mm is optimal.

[0054] Prepare the support plate material. The diameter of the support plate material should be 1.75mm or 2.85mm; 1.75mm is preferred.

[0055] Prepare the outsole material, using a tough and wear-resistant material. The diameter of the outsole material should be 1.75mm or 2.85mm; 1.75mm is optimal.

[0056] Step S4: Printing Platform Preparation

[0057] Clean the surface of the printing platform; apply glue or use a heated platform (temperature 50-100℃, optimal 70℃) to improve adhesion.

[0058] Step S5: Print according to the designed printing parameters. The multi-material printing process is as follows:

[0059] Step S5.1: Start the printer and preheat the printhead and platform:

[0060] The nozzle temperature for the soft material in the shoe midsole is controlled at 190-230℃, with an optimal temperature of 220℃; the nozzle temperature for the support plate 02 material is controlled at 220-260℃, with an optimal temperature of 240℃; and the nozzle temperature for the outsole 03 material is controlled at 230-270℃, with an optimal temperature of 250℃.

[0061] The platform temperature should be controlled between 50-100℃, with an optimal temperature of 70℃.

[0062] Step S5.2, according to the slicing parameters, refer to Figure 2 As shown, the printing process proceeds from bottom to top. First, the bottom layer of the outsole 03 is printed using a tough and wear-resistant material, with a printing fill rate of 20%-50%, ideally 40%. Then, the interlocking structure base is printed in a designated area of ​​the outsole 03. Simultaneously, the printing switches to the support plate 02 material to print the support plate structure. The thickness of the support plate 02 is 0.5-2mm, ideally 1mm, and the fill rate of the support plate 02 material is 80%-100%, ideally 90%.

[0063] When printing the midsole 01, the thickness of the midsole should be controlled at 30-40mm, with 35mm being optimal. The printing fill rate should be 30%-50%. The midsole adopts a zoned structure: the forefoot area uses a spiral structure with an optimal fill rate of 40%, providing rebound and propulsion; the heel area uses a honeycomb structure with an optimal fill rate of 30%, providing support and cushioning. This includes the area where it connects with the support plate 02 and the area 031 where it connects with the outsole 03 (e.g., ...). Figure 4 As shown, cross-linking interlocking is achieved.

[0064] The sole is printed layer by layer from bottom to top until the entire sole is completed. During the printing process, each nozzle automatically switches materials according to the model area. After printing, a multi-material interlocking one-piece sole is obtained.

[0065] Step S6: Post-processing

[0066] After printing, wait for the platform to cool to room temperature (about 20-30℃), then remove the sole, remove the support structure b, and perform sanding, cleaning, and other treatments on the sole surface.

[0067] Annealing can be performed as needed (temperature 60-80℃, time 1-2 hours) to improve material properties.

[0068] This invention discloses a one-piece molding printing method for a multi-material interlocking structure shoe sole. The multi-material interlocking structure improves the bonding strength of the various components of the sole, and tensile tests show good fracture strength at the joints. Production efficiency is improved, eliminating the need for molds and directly transforming digital models into products, shortening the development cycle by 50%-70%. Traditional processes have a development cycle of approximately 4-6 weeks, while this process takes approximately 1-2 weeks. Small-batch personalized customization production is possible, with production efficiency 2-3 times higher than traditional processes. Cost savings are achieved by eliminating mold manufacturing costs; for small-batch production (50-100 pairs), costs are reduced by 40%-60%. Material utilization is improved, reducing waste; traditional processes achieve a material utilization rate of approximately 60%-70%, while this process reaches 85%-95%.

[0069] In one preferred embodiment, step S5.2 involves the following control during printing:

[0070] Nozzle switching: Start the early switching in the area 0.2mm outside the boundary of the support plate 02 to ensure that the materials overlap at the junction with an overlap width of 0.15mm.

[0071] Flow control: The flow rate of material 02 in the support plate is increased to 105% in the interlocked zone to force melt filling, while the flow rate in the non-interlocked zone is 100%.

[0072] Temperature control: After the support plate 02 is printed, the printing platform is heated to promote molecular diffusion at the interface between the shoe midsole material and the support plate.

[0073] Interlocking structure: When printing the shoe midsole 01 material, the melt is embedded in the periphery 021 of the support plate (e.g., Figure 4 The interlocking area (as shown) is solidified within the groove to form a mechanical anchor;

[0074] Forefoot area: The midsole 01 has a filling rate of 40% and a spiral structure (spiral filling) to improve the resilience of the sole;

[0075] Arch area: The thickness of the support plate 02 is increased from 1mm to 1.2mm, which can improve the torsional resistance of the sole;

[0076] Heel area: The midsole has a 30% filling rate and a honeycomb structure, which can improve the cushioning and support of the sole.

[0077] It should be noted that, during the printing process, the outer contour of each component of the present invention is determined first, and then the material is filled within the corresponding outer contour.

[0078] In one preferred embodiment, the interlocking structure includes a sawtooth interlocking structure 05 that fits between phase layers (e.g., Figure 5 As shown), the mortise and tenon interlocking structure between phase layers 06 (as shown) Figure 6 (as shown) or a spiral interlocking structure with layered interlocking 07 (such as) Figure 7 (As shown).

[0079] Specifically, the support plate 02 and the midsole 01 are interlocked together by 3D printing, forming a first interlocking structure, specifically a serrated interlocking structure 05, which allows the soft and hard materials to interweave at the molecular level; the outsole 03 and the midsole 01 are interlocked together by 3D printing, forming a second interlocking structure, specifically a tenon and mortise interlocking structure, which prevents delamination under lateral shear force.

[0080] In one preferred embodiment, the support plate 02 is a carbon fiber plate or a nylon plate, the midsole 01 is a PEBA sole, and the outsole 03 is a TPU sole.

[0081] In one preferred embodiment, the tooth depth of the sawtooth interlocking structure 05 is 0.5 mm and the tooth pitch is 1.5 mm; the tenon and mortise interlocking structure 06 has a bottom width of 0.7 mm and a height of 0.3 mm.

[0082] In one preferred embodiment, the nozzle temperature of the support plate 02 is 245°C, the printing speed is 80 mm / s, and the interlayer cooling time is 3 seconds.

[0083] The nozzle temperature of the shoe midsole 01 is 215℃, the printing speed is 120mm / s, and the interlayer cooling time is 1s;

[0084] The printhead temperature of the shoe outsole 03 is 220℃, the printing speed is 60mm / s, the fill rate is 50%, the grid fill is used, and the interlayer cooling time is 2s.

[0085] This invention utilizes multi-head collaborative operation to achieve precise allocation and switching of different materials in the same printing process, meeting the material performance requirements of different parts of the shoe sole. By designing special interlocking geometric structures (such as convex-concave interlocking, mesh interlacing, etc.) at the material interfaces, mechanical interlocking is formed between different materials, improving the bonding strength and realizing the fusion of multiple materials.

[0086] The sole of the shoe needs to withstand complex dynamic stresses (impact, torsion, bending) during human movement. This process solves the problem of stress concentration at the interface of heterogeneous materials through a gradient interlocking design.

[0087] Layered printing and parameter optimization: Based on material properties and component functions, optimize the printing parameters of each layer (such as temperature, speed, infill rate, etc.) to ensure print quality and performance.

[0088] The product quality and performance of this invention are improved: the multi-material interlocking structure increases the bonding strength of the various parts of the sole by 30%-50%. Tensile tests show that the fracture strength at the joint can reach 25-30 MPa, while the traditional assembly process only achieves 15-20 MPa.

[0089] The addition of carbon fiber plates increases the torsional strength of the sole by 40%-60% and reduces the deformation of the sole by 30%-40% in bending tests.

[0090] The soft midsole material can be adjusted in hardness (e.g., Shore A hardness 40-60A) to provide better cushioning and support.

[0091] The outsole of shoe 03 uses a mesh structure with a filling rate of 50%.

[0092] The above embodiments and accompanying drawings are not intended to limit the product form and style of the present invention. Any appropriate changes or modifications made by those skilled in the art should be considered as not departing from the patent scope of the present invention.

Claims

1. A method of integrally forming a multi-material interlocking structural sole by printing, the method comprising: Includes the following steps: ​ Step S1: Design a three-dimensional model of the shoe sole, and determine the interlocking structure and interlocking area between the various components of the shoe sole. The shoe sole includes a midsole, a support plate, and an outsole. The support plate is located inside the midsole. Step S2: Slice the designed shoe sole into pieces with a thickness of 0.1~0.26mm, and set the printing parameters for each component material; Step S3: Material Preparation Prepare the shoe midsole material, using a soft material with a diameter of 1.75mm or 2.85mm; Prepare the support plate material, with a diameter of 1.75mm or 2.85mm; Prepare the outsole material; the diameter of the outsole material should be 1.75mm or 2.85mm. Step S4: Printing Platform Preparation Clean the surface of the printing platform; Step S5: Print according to the designed printing parameters. The multi-material printing process is as follows: Step S5.1: Start the printer and preheat the printhead and platform: The nozzle temperature for the soft material in the shoe midsole is controlled at 190-230℃, the nozzle temperature for the support plate material is controlled at 220-260℃, and the nozzle temperature for the outsole material is controlled at 230-270℃. The platform temperature should be controlled between 50-100℃; Step S5.2: According to the slicing parameters, first print the bottom layer of the shoe outsole using a tough and wear-resistant material with a printing fill rate of 20%-50%. Print the interlocking structure base in the designated area of ​​the shoe outsole. At the same time, switch to the support plate material to print the support plate structure. The support plate thickness is 0.5-2mm, and the fill rate of the support plate material is 80%-100%. When printing the shoe midsole, the thickness of the shoe midsole is controlled to be 30-40mm, the printing fill rate is 30%-50%, and cross-linking and interlocking are achieved with the joint area of ​​the support plate and the joint area of ​​the shoe outsole. The interlocking structure includes a sawtooth interlocking structure between phase layers, a tenon and mortise interlocking structure between phase layers, or a spiral interlocking structure with overlapping phase layers. The sole is printed layer by layer until it is completed. During the printing process, each nozzle automatically switches materials according to the model area. After printing, a multi-material interlocking one-piece molded sole is obtained. Step S6: Post-processing After printing is complete, wait for the platform to cool to room temperature before removing the shoe sole.

2. The method for integral molding and printing of a multi-material interlocking structure shoe sole as described in claim 1, characterized in that: In step S5.2, the printing process is controlled as follows: Nozzle switching: Initiate early switching in an area 0.2mm outside the support plate boundary to ensure that the material overlaps at the junction with an overlap width of 0.15mm; Flow control: The flow rate of the support plate material is increased to 105% in the interlocked zone until the melt is filled, and the flow rate is 100% in the non-interlocked zone; Temperature control: After the support plate is printed, the printing platform is heated to diffuse the molecules at the interface between the shoe midsole material and the support plate. Interlocking structure: When the shoe midsole material is printed, the melt is embedded in the groove of the interlocking area around the support plate and solidifies to form a mechanical anchor; Forefoot area: The midsole has a 40% filling rate and a spiral filling structure; Arch area: The thickness of the support plate has been increased from 1mm to 1.2mm; Heel area: The midsole has a filling rate of 30% and a honeycomb structure.

3. The method for integral molding and printing of a multi-material interlocking structure shoe sole as described in claim 1, characterized in that: The support plate and the midsole are connected by a serrated interlocking structure; the outsole and the midsole are connected by a tenon and mortise interlocking structure.

4. The method for integral molding and printing of a multi-material interlocking structure shoe sole as described in claim 1, characterized in that: The support plate is a carbon fiber plate or a nylon plate, the midsole is a PEBA sole, and the outsole is a TPU sole.

5. The method for integral molding and printing of a multi-material interlocking structure shoe sole as described in claim 1, characterized in that: The tooth depth of the sawtooth interlocking structure is 0.5 mm and the tooth pitch is 1.5 mm; the tenon and mortise structure is 0.7 mm wide and 0.3 mm high.

6. The method for integral molding and printing of a multi-material interlocking structure shoe sole as described in claim 1, characterized in that: The outsole of the shoe has a mesh structure and a fill rate of 50%.

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