Seamless integrated forming method for silica gel node and sole

Abstract

The invention belongs to the technical field of intelligent manufacturing, and relates to a seamless integrated forming method for silica gel nodes and soles, which comprises the following steps: extracting data of a joint interface of the nodes and the soles from a sole prototype, evaluating the continuity of the joint interface by adopting an image analysis technology, judging a bonding strength index; if the bonding strength index is lower than a preset threshold value, the structure of the sole prototype is corrected through a hot-pressing fusion technology, and an enhanced sole assembly is obtained; performing a dynamic load test according to the enhanced sole assembly, simulating a motion scene by the test to obtain a stress distribution data set, and determining the overall stability level of the sole assembly; the overall stability level is compared with a preset standard, if the overall stability level meets the requirement, a final product is manufactured through a batch production process, and the sneaker sole meeting the precise layout is obtained.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of intelligent manufacturing, and particularly relates to a seamless integration forming method for a silica gel node and a sole. BACKGROUND

[0002] In the field of sports shoe manufacturing, developing high-performance, comfortable and durable products has always been an important goal pursued by the industry. Sports shoes, as the core equipment in daily wear and professional sports, their design and manufacturing directly affect the wearer's experience and sports performance. With the increasing demand of consumers for the functionality and personalization of shoes, the innovation of manufacturing process has become the key driving force for the development of the industry.

[0003] However, the traditional manufacturing method gradually exposes many shortcomings in response to these demands, and technical breakthroughs are needed to meet the modern production and use standards. Currently, the silica gel nodes used to provide cushioning and support in sports shoes are mostly assembled in steps, that is, the nodes are first made separately, and then fixed to the sole by adhesion or sewing. Although this method is simple to operate, it faces many challenges in actual application. The assembly process results in a less firm connection between the nodes and the sole, and the nodes may come loose or even fall off during long-term use or high-intensity exercise. In addition, this method also has the problem of poor touch transmission, and the contact surface between the nodes and the sole will produce resistance, affecting the efficiency of force transmission, and greatly reducing the response speed and comfort of the shoes. More importantly, the traditional process often has difficulty in ensuring the consistency of shape and spacing when facing the precise layout of multiple nodes, and highly depends on manual adjustment in production, which is low in efficiency and unstable in quality. In this context, the core technical difficulty faced by the industry is how to realize the seamless combination of silica gel nodes and soles. As a key component of the sole cushioning and support, the connection strength of the silica gel node and the sole directly determines the overall stability and durability of the shoe. If a tight combination cannot be achieved, the node is likely to displace when under stress, thereby affecting the wearer's sports experience. The deeper problem is that the distribution of multiple nodes (such as 22 nodes) on the sole requires extremely high precision, otherwise the interaction between the nodes will produce uneven stress, causing premature wear or failure in local areas. For example, during running, if a node is positioned off the design standard, it may cause uneven stress on the foot, increasing the risk of spraining.

[0004] Therefore, how to ensure the seamless integration forming of multiple silica gel nodes and soles in the manufacturing process, while ensuring the accuracy and consistency of node distribution, has become a key problem in improving the performance and production efficiency of sports shoes. The solution to this problem not only concerns the improvement of product quality, but also directly affects whether the manufacturing process can adapt to the trend of intelligentization and high efficiency of the industry. SUMMARY

[0005] The application provides a seamless integrated forming method for a silica gel node and a sole, mainly comprising:

[0006] Collecting sole basic structure data by a digital scanning device, wherein the basic structure data includes a sole contour and surface details, processing point cloud information in the basic structure data by a three-dimensional modeling technology to obtain a three-dimensional geometric model of the sole, extracting surface curvature features according to the three-dimensional geometric model of the sole, wherein the curvature features reflect bending shapes and pressure distribution areas of the sole, determining an initial distribution scheme of silica gel nodes by a simulation analysis technology, wherein the silica gel nodes are embedded points of silica gel material for providing foot support and impact buffering, adjusting coordinate parameters of the silica gel nodes by an optimization calculation technology if a node spacing deviation in the initial distribution scheme exceeds a preset threshold, wherein the adjustment comprehensively considers overall balance of the sole to obtain an optimized node position configuration, generating silica gel material injection paths for the optimized node position configuration, wherein the injection paths are used to guarantee material distribution uniformity, constructing an integrated forming mold by an additive manufacturing technology to obtain a sole prototype containing embedded nodes, extracting node and sole combination interface data from the sole prototype, wherein the interface data covers contact surface textures and connection point features, evaluating continuity of the combination interface by an image analysis technology to determine a combination strength index, correcting a structure of the sole prototype by a hot-pressing fusion technology if the combination strength index is lower than a preset threshold to obtain an enhanced sole assembly, performing dynamic load testing according to the enhanced sole assembly, wherein the testing simulates a motion scene to obtain a stress distribution data set and determines an overall stability level of the sole assembly, comparing the overall stability level with a preset standard, and if the overall stability level meets requirements, manufacturing a final product by a mass production process to obtain a sports sole meeting accurate layout.

[0007] The technical scheme provided by the embodiment of the application can have the following beneficial effects:

[0008] The application discloses a seamless integrated forming method for silica gel nodes and soles, and aims at the problems of uneven distribution of silica gel nodes in traditional sole manufacturing, which leads to unstable support, large pressure distribution deviation and insufficient overall stability level. The problems are related to challenges such as node spacing deviation exceeding the standard, low bonding strength and uneven stress under dynamic load. The method comprises the following steps: collecting sole basic structure data and generating a geometric model by using a three-dimensional modeling technology, extracting surface curvature features and simulating and analyzing an initial distribution scheme, optimizing node coordinates to ensure balance if the deviation exceeds a threshold value, generating an injection path and constructing an integrated forming mold by using additive manufacturing, extracting interface data to evaluate the bonding strength, and hot-pressing fusion to correct the structure if the bonding strength is lower than a threshold value, and finally performing dynamic load testing to compare the stability level to determine batch production, so as to solve the above problems, realize accurate layout and uniform distribution of silica gel nodes, and finally improve the foot support, impact buffering and overall stability of the sole, and obtain a high-performance sports sole. BRIEF DESCRIPTION OF DRAWINGS

[0009] Fig. 1 A flowchart of the seamless integrated forming method for silica gel nodes and soles.

[0010] Fig. 2 A schematic diagram of the seamless integrated forming method for silica gel nodes and soles.

[0011] Fig. 3 Another schematic diagram of the seamless integrated forming method for silica gel nodes and soles. DETAILED DESCRIPTION

[0012] In order to further understand the content of the application, the application will be described in detail in conjunction with the drawings and examples. It can be understood that the specific examples described herein are only used to explain the related application, and not to limit the application. In addition, it should be noted that, in order to facilitate description, only the parts related to the application are shown in the drawings.

[0013] As Figs. 1-3 The seamless integrated forming method for silica gel nodes and soles can specifically comprise the following steps:

[0014] In step S101, the sole basic structure data is collected by a digital scanning device, the basic structure data includes the sole contour and surface details, the point cloud information in the basic structure data is processed by using a three-dimensional modeling technology, and a three-dimensional geometric model of the sole is obtained.

[0015] The basic structure data of the shoe sole is collected by a digital scanning device, the basic structure data including the sole contour and surface details, the point cloud information in the basic structure data is processed by a three-dimensional modeling technology, the three-dimensional modeling technology generates a surface mesh by meshing the point cloud to obtain a three-dimensional geometric model of the shoe sole. According to the three-dimensional geometric model of the shoe sole, the material distribution characteristics are extracted from the model, and the material distribution characteristics are processed by a finite element analysis method, the finite element analysis method calculates the stress value by dividing the grid element and applying the load to obtain a stress distribution map of the shoe sole. Through the stress distribution map of the shoe sole, the thickness data of the wear-resistant layer of the shoe sole is obtained for the high stress area in the distribution map, it is judged whether the thickness data is lower than the preset threshold value, if lower than the preset threshold value, the thickness parameter of the high stress area is adjusted to obtain the optimized shoe sole structure parameter. According to the optimized shoe sole structure parameter, the shoe sole customized production data is generated in combination with the three-dimensional geometric model of the shoe sole, and the production data is used to determine the final three-dimensional geometric model of the shoe sole.

[0016] Specifically, in one embodiment, the basic structure data of the shoe sole is collected by a digital scanning device, first, a suitable scanning environment needs to be prepared, for example, the shoe sole is placed on a stable platform to avoid vibration interference with data accuracy. The digital scanning device can be a laser scanner or a structured light scanner, which captures the physical characteristics of the shoe sole by emitting a light beam or laser. The basic structure data includes the sole contour, that is, the shape boundary and size of the sole, and the surface details, such as the depth and pattern distribution of the sole pattern.

[0017] Specifically, the scanning process starts from the front end of the shoe sole and gradually covers the entire bottom area to ensure that the collected data points are evenly distributed. This acquisition method is suitable for various footwear, such as the sole design of sports shoes or leather shoes, and can achieve high-precision structure capture. Through this step, the original data can be obtained to provide a basis for subsequent processing. Further, the point cloud information refers to the set of three-dimensional coordinate points collected by the scanning device, which represents the spatial position of the shoe sole surface, for example, each point contains x, y, z coordinate values, which together form a dense point cloud.

[0018] It should be noted that the point cloud information may contain noise, such as abnormal points caused by light reflection or device errors, so preliminary filtering is required before processing. When the point cloud information is processed by a three-dimensional modeling technology, the point cloud is first registered, that is, the point cloud data of multiple scanning angles is aligned into a unified coordinate system. This step ensures the integrity of the model, for example, when processing the sole of sports shoes, the point clouds of the side and bottom can be integrated to avoid data loss.

[0019] In one possible implementation, the three-dimensional modeling technique specifically includes a surface reconstruction algorithm, such as using a Poisson surface reconstruction method, to convert the point cloud into a mesh model. The specific process is to estimate the normal vector from the point cloud, i.e. to calculate the surface direction of each point, and then to generate a continuous curved surface based on these normal vectors.

[0020] Exemplarily, for the modeling of the sole of a casual shoe, this method can accurately restore the geometry of the anti-skid pattern, ensuring that the model reflects the real surface details. Through this processing, the three-dimensional geometric model of the sole obtained is an editable digital representation, supporting subsequent analysis or manufacturing applications.

[0021] Preferably, when collecting the sole base structure data, multi-angle scanning can be combined to improve accuracy.

[0022] For example, for the sole of a boot, due to its large thickness, the scanning device can simultaneously collect data from above and from the side to capture the curve changes of the profile and the groove texture of the surface details. This multi-angle approach helps to reduce blind spots and ensure the comprehensiveness of the base structure data. The point cloud information in this scenario will be richer, containing more surface points, thereby providing reliable input for modeling.

[0023] Specifically, the principle of processing the point cloud information is to convert discrete points into continuous geometric bodies, such as connecting the point cloud into triangular facets through a triangulation algorithm to form a three-dimensional geometric model of the sole. In processing the sole of a running shoe, this process emphasizes the curved surface reconstruction of the buffer zone, ensuring that the model captures the deformation characteristics of the elastic material. This technology can achieve high fidelity of the model, supporting optimization of the sole design. For example.

[0024] In one embodiment, for the collection of the sole of a high-heeled shoe, a handheld digital scanning device is used for rapid scanning, and the base structure data focuses on the elongated profile and smooth surface details. Then, a three-dimensional modeling technique is used to denoise and simplify the point cloud information, such as removing isolated points and reducing the point density, to improve processing efficiency. The final model can be used for virtual try-on or production simulation. Further.

[0025] It can be understood that the flexibility of the three-dimensional modeling technique allows the integration of texture mapping, i.e. superimposing color or material information on the geometric model.

[0026] For example, for a sandal sole, surface color data can be collected simultaneously when processing the point cloud, generating a textured model. This extension enhances the practicality of the model, providing more intuitive visual feedback in footwear design. In another implementation, for modeling a child's shoe sole, the scanning device needs to adjust the resolution to capture small contours and fine details. Point cloud processing includes clustering algorithms that group similar points to identify surface areas, thereby constructing an accurate geometric model. This method demonstrates the versatility of the technology, which can adapt to different sole sizes and complexities.

[0027] It should be noted that through the above acquisition and modeling process, the digital reproduction of the sole structure can be realized, for example, in the sole wear resistance test, using the model for simulation analysis, thereby improving the design efficiency. This technical effect is due to the accuracy of data processing, ensuring that the model can be reliably applied to actual scenarios.

[0028] Step S102, extracting surface curvature features from the three-dimensional geometric model of the sole, the curvature features reflect the bending shape and pressure distribution area of the sole, and the initial distribution scheme of the silica gel node is determined by using simulation analysis technology, the silica gel node is a silica gel material embedded point for providing foot support and impact cushioning.

[0029] Through the geometric model of the sole, the surface curvature features are obtained, and the bending shape is reflected. According to the bending shape reflection, finite element analysis is used, in which the finite element analysis is used to divide the grid and calculate the stress distribution to determine the pressure distribution area. For the pressure distribution area, simulation analysis technology is used, in which the simulation analysis technology calculates the node position by load simulation to obtain the silica gel node distribution. Through the silica gel node distribution, a grid optimization method is used, in which the grid optimization method adjusts the node density to determine the initial scheme to obtain the silica gel material point position.

[0030] Specifically, in one embodiment, a three-dimensional geometric model of the sole is first obtained, which is constructed by a scanning device or CAD software, and is used to represent the overall shape and surface details of the sole.

[0031] Specifically, the three-dimensional geometric model can adopt a meshed representation, such as a triangular mesh structure, where each mesh point contains coordinate information to reflect the actual geometric shape of the sole. The construction process of such a model includes data acquisition and surface reconstruction, such as scanning the physical sole using a laser scanner to generate point cloud data, and then converting it into a continuous three-dimensional model through surface fitting algorithms. In this way, it is ensured that the model accurately captures the curved parts and potential pressure areas of the sole, providing a basis for subsequent feature extraction. Further, surface curvature features are extracted from the three-dimensional geometric model of the sole. Curvature features mainly include principal curvature and Gaussian curvature, which can quantify the bending degree of the surface in different directions, thus reflecting the bending shape and pressure distribution area of the sole.

[0032] For example, principal curvature describes the maximum and minimum bending values of the surface in orthogonal directions, while Gaussian curvature is the product of the two, used to identify convex and concave regions. In the extraction process, the model surface is first discretized, divided into multiple sampling points, and then the local curvature of each point is calculated. In specific implementation, finite difference method can be used to calculate the curvature tensor by differentiating the coordinates of adjacent mesh points, thus deriving the principal curvature value. This extraction method helps to identify the bending shape of the arch part of the sole, which usually bears high pressure and needs targeted support. By analyzing the curvature distribution map, the pressure concentration area can be visualized, such as the higher positive curvature of the forefoot part of the sole indicating the potential impact area, providing data support for optimization design. The detailed steps of this process include surface parameterization, curvature calculation and feature mapping, ensuring that the features accurately reflect the geometric characteristics, which helps to improve the comfort and durability of the sole in the field of footwear manufacturing.

[0033] Preferably, after extracting the curvature features, an initial distribution scheme of the silica gel nodes is determined using simulation analysis techniques. Simulation analysis techniques here refer to finite element analysis methods used to simulate the interactive mechanical behavior of the foot and the sole.

[0034] Specifically, first, a finite element model is established, the three-dimensional geometric model of the sole is imported into the simulation software, and boundary conditions such as foot pressure load and material properties are applied. Silica gel nodes are defined as silica gel material embedding points, which are designed to provide foot support and impact cushioning, such as embedding foam silica gel in the sole to absorb impact force during walking. In the simulation process, the pressure distribution is calculated by iteration to identify high stress areas, and then the node positions are optimized according to the curvature features.

[0035] For example, if the curvature analysis shows that the heel area has higher negative curvature, indicating that the concave shape is prone to accumulate pressure, then silica gel nodes are densely arranged in this area. The simulation steps include mesh division, load application and stress solution, and finally generate an initial distribution scheme such as a node coordinate matrix. This technology is widely used in sports shoe design and can reduce foot fatigue.

[0036] In one possible implementation, the simulation adjustment is made for different shoe type scenarios.

[0037] For example, in the embodiment of running shoes, the forefoot cushioning is emphasized, so the silica gel nodes are preferentially arranged in the larger curvature area of the forefoot according to the curvature feature, and the effect of the distribution scheme under dynamic load is verified through simulation analysis. The specific process involves setting the mechanical parameters of the walking cycle, calculating the impact force absorption rate of the nodes, and ensuring the universality of the scheme.

[0038] It should be noted that the distribution scheme of silica gel nodes can be further implemented through iterative optimization.

[0039] For example, after the initial scheme is generated, multiple simulation cycles are performed, and the node density is adjusted to match the pressure distribution reflected by the curvature feature. This method is also applicable in the field of casual shoes, providing personalized support. For example.

[0040] In one embodiment, for hiking shoes, the curvature extraction focuses on the adaptability of uneven terrain, and the simulation analysis considers the inclined load to determine the distribution of silica gel nodes on the side of the sole to enhance stability. Further, the logic of the whole process is that the curvature feature is directly input into the simulation analysis as the basis for determining the node distribution, thereby forming a closed technical chain. In another embodiment, user foot type data is combined to enhance the accuracy of the simulation, such as importing a personalized three-dimensional foot model and superimposing it with the sole model for joint simulation to optimize the silica gel node scheme.

[0041] It can be understood that this technical scheme can achieve efficient support design and reduce material waste in shoe production.

[0042] In step S103, if the node spacing deviation in the initial distribution scheme exceeds the preset threshold, the coordinate parameters of the silica gel nodes are adjusted by optimization calculation technology, and the adjustment comprehensively considers the overall balance of the sole to obtain the optimized node position configuration.

[0043] By scanning the surface of the sole, the initial coordinates of the silica gel nodes are obtained, and the node spacing deviation value is determined. If the node spacing deviation value exceeds the preset threshold, the gradient descent algorithm is used to adjust the coordinate parameters with the silica gel node coordinates as input to obtain the preliminary adjustment coordinates. According to the preliminary adjustment coordinates, the sole pressure distribution mapping is calculated, and the overall balance index is judged by comparing the mapping value with the balance threshold value. The silica gel node coordinates are refined through the overall balance index to obtain the optimized node position configuration.

[0044] Specifically, in one embodiment, the initial distribution scheme is based on the geometric model of the sole. First, the preliminary positions of the silica gel nodes are generated by digital tools, and these nodes usually correspond to key support points of the sole, such as the forefoot, arch, and heel regions.

[0045] It should be noted that the node spacing deviation refers to the difference between the actual spacing and the ideal uniform distribution. If the deviation exceeds the preset threshold, such as 5 millimeters, the adjustment process is triggered. This threshold can be configured according to the specific needs of shoe types such as sports shoes or casual shoes to ensure the preliminary rationality of the distribution.

[0046] Specifically, the optimization calculation technology involves an iterative algorithm to adjust the coordinate parameters of the silica gel nodes. For example.

[0047] In one possible implementation, a gradient descent method is used to simulate the fine-tuning of node positions. First, the current position vector of each node is calculated, and then a correction vector is generated based on the deviation value. This technique can be understood as a numerical optimization process in which coordinate parameters such as x, y, z axis values are gradually updated to minimize the spacing deviation. For example, for the sole of a pair of running shoes, if the spacing deviation of the forefoot nodes reaches 7 millimeters, the system will gradually move the nodes towards the equilibrium direction through multiple iterative calculations, with each adjustment step controlled within 1 millimeter to avoid excessive correction leading to structural instability. Further, the adjustment takes into account the overall balance of the sole, which is a key innovation point in the optimization process. Balance refers to the uniform distribution of the sole when under pressure, for example, by simulating the mechanical response during walking or running to evaluate.

[0048] In one embodiment, a mechanical model of the sole is first established, with the silica gel nodes regarded as elastic support points, and then the overall center of gravity offset is calculated. If the offset exceeds the threshold, such as 2 degrees, a weight factor is introduced in the coordinate adjustment, for example, higher weights are assigned to the nodes in the arch area to ensure the stability of the sole during dynamic use. This consideration can bring technical effects, i.e., improving the durability and wearing comfort of the sole, without being limited to static distribution.

[0049] Preferably, a multi-round verification mechanism can be introduced in the adjustment process.

[0050] For example, a simulation test is performed on the optimized node position configuration to check if the spacing deviation is reduced below the threshold and to evaluate the balance indicators such as pressure distribution uniformity. If in the implementation scenario of a pair of hiking shoes, the initial deviation is 6 millimeters, after optimization, the spacing is stabilized within 3 millimeters, and the center of gravity offset of the sole is reduced to 1 degree, which indicates that the adjustment effectively supports the balance requirements of the sole in rugged terrain. In another implementation, for different shoe scenarios such as basketball shoes, the optimization calculation can adjust the parameters in combination with user feedback data.

[0051] Specifically, the pressure point data in the wearing test is collected first, and then these measured values are integrated into the coordinate adjustment, for example, the node spacing threshold of the high pressure area is set to 4mm to achieve more fine balance optimization. This method shows the universality of the technical solution, which can adapt to various sole design requirements in the same field.

[0052] For example, in the optimization of a pair of daily casual shoes, if the heel node spacing deviation in the initial scheme reaches 8mm, the system calculates the displacement vector of each node through optimization technology, and comprehensively balances factors such as sole thickness uniformity, and finally obtains a node position configuration in which all spacing is controlled within the threshold. This configuration ensures the stability of the sole during long-term walking.

[0053] It can be understood that the optimized node position configuration can be directly imported into the manufacturing process, for example, used for 3D printing of sole molds, so as to realize seamless connection from design to production.

[0054] In one embodiment, for the sole of children's shoes, the threshold can be relaxed to 6mm to adapt to the changes of the growing feet, and the body balance is adjusted at the same time to prevent lateral wear. Further, the technical solution can be extended to the custom sole scene, for example, generating an initial distribution according to individual foot scan data, and if the deviation is out of tolerance, optimizing and adjusting the coordinates to ensure that the balance meets individual needs. This extension remains within the field of footwear manufacturing, enhancing the flexibility of the solution.

[0055] In one embodiment, the optimization calculation technology can use a gridding method to divide the sole into multiple regional grids, and the deviation of the node spacing in each grid is calculated independently, and then the coordinates are adjusted globally to maintain the overall balance.

[0056] For example, in the design of tennis shoes, this method can handle the deviation caused by lateral movement to obtain an optimized configuration.

[0057] It should be noted that through the above adjustment, the final node position configuration can support various functional requirements of the sole, such as cushioning and support, and the objective implementation of the optimization process ensures the reliability of the technical solution.

[0058] Step S104, generating a silica gel material injection path for the optimized node position configuration, the injection path is used to ensure material distribution uniformity, and an integrated forming mold is constructed using additive manufacturing technology to obtain a sole prototype containing embedded nodes.

[0059] The node position configuration is used to obtain a silica gel injection path from the node strength verification, and the material distribution uniformity is determined. According to the silica gel injection path, an integrated forming mold is constructed by using additive manufacturing, and the path uniformity guarantee is obtained. If the integrated forming mold is fused with the material distribution uniformity, the embedded node setting is obtained by prototype density analysis, and the sole prototype is generated. For the embedded node setting, the manufacturing path optimization is obtained from the mold material fusion, and the node strength verification is determined. Through the manufacturing path optimization, the prototype density analysis is fused with the path uniformity guarantee, and the sole prototype containing embedded nodes is obtained.

[0060] Specifically, in one embodiment, for the optimized node position configuration, it is necessary to generate a silica gel material injection path first. The design of this path aims to guarantee the uniformity of the distribution of materials in the sole structure.

[0061] Specifically, the node position configuration generally refers to the optimized arrangement of embedded sensor nodes in the sole, such as the placement of pressure sensor nodes in the arch and heel areas to monitor gait data. The process of generating the injection path is based on these node positions, and the path is planned by simulating a material flow model.

[0062] Exemplarily, the finite element analysis method can be used to simulate the flow behavior of silica gel materials, in which the path extends from the center of the sole to the periphery, ensuring that the material bypasses the nodes without causing cavities or accumulation. Further, the generation of the injection path takes into account the viscosity and flow characteristics of the silica gel material.

[0063] For example, in the design of a sole prototype, the path can be divided into a main injection channel and branch channels, the main channel connects the mold inlet, and the branch channels are adjusted according to the node positions to avoid excessive concentration of materials around the nodes.

[0064] It should be noted that this path planning can be realized by computer-aided design software, after inputting the optimized node coordinates, the software calculates multiple alternative paths and selects the one with the best uniformity. In specific implementation, uniformity can be evaluated by material density distribution simulation to ensure that the silica gel filling rate of the entire sole area remains above 90%, thereby improving the overall comfort and durability of the sole.

[0065] Preferably, an integrated forming mold is constructed by using additive manufacturing technology. This technology uses 3D printing equipment to layer the mold structure, and the mold interior is pre-reserved with an injection path and a node embedding cavity.

[0066] In one possible implementation, the mold material is selected as photosensitive resin, and the mold is constructed by selective laser sintering method, so as to ensure that the precision of the mold reaches the level of 0.1 millimeter. The integrated mold can seamlessly integrate the node positions and avoid the leakage risk caused by the traditional mold splicing. The construction process includes scanning and optimizing the node configuration, generating a digital model of the mold, and then performing printing output. The whole process is suitable for prototype development of sports shoes or medical correction shoes in the field of sole manufacturing.

[0067] In one embodiment, the process of obtaining a sole prototype containing embedded nodes is as follows: first, fix the optimized nodes at the preset positions in the mold, and then inject the silica gel material through the generated injection path. After the material is injected, a curing process is performed, for example, placing in a constant temperature environment for 24 hours. Finally, the sole prototype is demolded, in which the nodes such as wireless sensors are embedded inside the silica gel to form an integrated structure.

[0068] It can be understood that this prototype can be used to test the gait analysis function and improve the intelligence of the sole in actual application, for example, real-time monitoring of foot pressure distribution to prevent sports injuries.

[0069] Specifically, for different implementation scenarios of different sole sizes, for example, adult sports shoe prototype, the injection path can be adjusted to have a main path length of 80% of the length of the sole, and the branch path covers the node dense area. In the child sole prototype, the path design pays more attention to the uniform filling of the soft area to adapt to the growth demand. These scenarios demonstrate the universality of the technical solution in the field of sole manufacturing, which ensures uniform distribution of materials through path optimization, and finally realizes effective integration of durability and functionality.

[0070] In step S105, the combination interface data of the nodes and the sole from the sole prototype is extracted, the interface data covers the contact surface texture and the connection point feature, the continuity of the combination interface is evaluated by using image analysis technology, and the combination strength index is judged.

[0071] The combination interface data of the nodes and the sole from the sole prototype is obtained, the contact surface texture and the connection point feature are extracted by using an edge detection algorithm, and the interface continuity index is obtained. For the interface continuity index, the uniformity of the combination interface is evaluated by using optical flow analysis, and the continuity score is determined. According to the continuity score, if the score is lower than a preset threshold, the node position parameter is adjusted, and the optimized combination interface data is obtained. By comparing the connection point feature and the texture change through the optimized combination interface data, the combination strength index is judged.

[0072] Specifically, in one embodiment, the combination interface data of the nodes and the sole from the sole prototype is extracted, first, a digital model of the sole prototype is obtained by using a scanning device. The interface data covers the contact surface texture and the connection point feature.

[0073] For example, the contact surface texture refers to the microstructure of the sole surface in contact with the node contact area, such as the concave-convex pattern or material density distribution, while the connection point feature includes the specific location and shape parameters of the node embedded in the sole. This extraction process is based on three-dimensional modeling software, which analyzes the prototype slices to identify the interface boundary. Further, the extraction process can be divided into two stages: data collection and feature identification. In the data collection stage, a high-resolution camera or laser scanner is used to capture the sole prototype image, ensuring a resolution of 0.1 millimeters to cover the fine texture. Feature identification is achieved through software algorithms processing the image.

[0074] For example, edge detection methods are used to locate the connection points and calculate the roughness value of the texture. The interface data extracted in this way provides a basis for subsequent evaluation, ensuring that the combination of nodes such as studs and soles in the design of sports shoes or casual shoes prototypes in footwear manufacturing is accurately characterized.

[0075] Preferably, image analysis techniques are used to evaluate the continuity of the combination interface.

[0076] Specifically, the image analysis technique involves a continuity evaluation algorithm that first converts the extracted interface data into a grayscale image and then applies the Sobel operator to detect edge continuity. By calculating the number of connected components of edge pixels, the uniform continuity of the interface is evaluated.

[0077] For example, if the number of connected components is less than a threshold of 5, it is considered to have good continuity. This technique is widely used in sole prototype verification and can identify potential combination defects such as bubbles or cracks.

[0078] In one possible implementation, continuity evaluation can be extended to different sole material scenarios.

[0079] For example, for rubber sole prototypes, the algorithm adjusts parameters to accommodate flexible textures, while for EVA material soles, the density analysis of connection points is emphasized. This diversification ensures the versatility of the technical solution in the footwear field, such as application to running shoes or boot prototypes, avoiding evaluation bias caused by material differences.

[0080] It should be noted that the judgment of the combination strength indicator is based on the continuity evaluation results. The specific process includes quantitative indicator calculation.

[0081] For example, the continuity score is compared with a preset threshold, and the strength index is generated by combining the texture roughness and the number of connection points. If the continuity score is higher than 80% and the connection point features are uniform, the strength indicator is determined to be high. This judgment helps optimize node design in sole production and achieve more stable footwear products, for example.

[0082] In one embodiment, for a pair of hiking shoe prototypes, after extracting interface data, image analysis shows that the contact surface texture continuity reaches 90%, the connection point features are not broken, and the strength index is judged to be excellent, thereby guiding the production adjustment of the gluing process. Further, the method can be integrated into an automated system and repeatedly applied in the iterative design of shoe sole prototypes.

[0083] For example, by extracting data through multiple scans, gradually optimizing interface continuity, and judging the improvement effect of the strength index, such as from 60% to 85%, this provides reliable support in footwear quality control. In another implementation, for leather shoe sole prototypes, the extraction process emphasizes texture color difference analysis, and image technology integrates light compensation when evaluating continuity to accurately judge the strength index and ensure applicability in high-end footwear manufacturing.

[0084] It can be understood that these embodiments cover different stages of shoe sole prototypes, such as initial design or finished product inspection, demonstrating the flexibility of the technical solution without going beyond the field of footwear.

[0085] Step S106, if the bonding strength index is lower than the preset threshold, the structure of the shoe sole prototype is modified by hot pressing fusion technology to obtain an enhanced shoe sole assembly.

[0086] The surface data of the shoe sole prototype is obtained by a scanning device, the bonding point density and material uniformity are extracted from the surface data, and the bonding strength index is calculated. If the bonding strength index is lower than the preset threshold, hot pressing fusion technology is used to apply uniform pressure and temperature to the prototype structure, and fusion parameters are adjusted to modify weak areas to obtain an enhanced shoe sole assembly.

[0087] Specifically, in one embodiment, the evaluation of the bonding strength index is based on the adhesion test results between the material layers of the shoe sole prototype, such as measuring the force required for material separation by a tensile testing machine, thereby quantifying the bonding strength.

[0088] Specifically, if the measured bonding strength index is lower than the preset threshold, such as a threshold of 50 Newtons per square centimeter, hot pressing fusion technology is started for modification. This technology involves placing the shoe sole prototype in a hot pressing device, applying uniform heat and pressure, allowing the molecules between the material layers to rearrange and fuse.

[0089] For example, in the manufacturing scenario of sports shoe soles, the shoe sole prototype may include a rubber bottom layer and a foam middle layer, and if the bonding strength is insufficient, hot pressing fusion technology can be used to heat to 120 degrees Celsius and apply 2 megapascal pressure for 5 minutes to enhance the adhesion between the layers. This way ensures the stability of the shoe sole under high intensity use.

[0090] In one possible implementation, the hot-pressing fusion process can be adjusted to adapt to different shoe types, for example, a casual shoe sole can use a lower temperature, such as 100 degrees Celsius, to avoid material deformation, while an outdoor shoe sole can increase the pressure to 3 megapascals to improve wear resistance.

[0091] It should be noted that the modified sole assembly is structurally reinforced through this technology and can better withstand impact loads during subsequent assembly.

[0092] Preferably, in another embodiment, for a multi-layer composite sole prototype, if the index is below the threshold value, the hot-pressing fusion can be performed in steps, first fusing the inner layer and then processing the outer layer to ensure overall uniformity.

[0093] It can be understood that this correction method is applicable to various sole materials, such as polyurethane or ethylene-vinyl acetate copolymer, demonstrating the universality of the technical solution in the field of footwear manufacturing.

[0094] In one embodiment, after hot-pressing fusion, the reinforced sole assembly is subjected to a second test, and if it still does not meet the requirements, the process can be repeated until the requirements are met, thereby improving production efficiency.

[0095] Step S107, according to the reinforced sole assembly, a dynamic load test is performed to simulate a motion scenario to obtain a stress distribution data set and determine the overall stability level of the sole assembly.

[0096] By constructing a motion scenario to obtain initial load data, stress distribution collection points are determined for the dynamic load simulation, and a preliminary data set is obtained; data noise filtering is performed using the preliminary data set, and a purified distribution is obtained from the stress distribution collection; a load peak value recognition result is determined; according to the purified distribution, scene parameter adjustment is performed, and distribution data set fusion is determined for the load peak value recognition, and an enhancement verification index is obtained; by calculating the index correlation of the enhancement verification index, the overall stability level is determined for the stability threshold setting, and a sole assembly durability evaluation is obtained.

[0097] Specifically, in one embodiment, a dynamic load test is performed on the reinforced sole assembly, first preparing test equipment including a load simulator and a sensor array. The sole assembly can be reinforced with rubber and foam composite material, and the test is designed to verify its performance under repeated impact.

[0098] Specifically, the sole is fixed on a test platform, and periodic pressure is applied by the load simulator to simulate the ground reaction force when the user is walking or running.

[0099] For example, in a simulated walking scenario, the load frequency is set to 1-2 times per second, and the pressure range is 500-1000 Newtons to cover the intensity of daily activities. Further, various motion scenarios are tested to obtain a comprehensive stress distribution dataset.

[0100] In one possible implementation, a running scenario is simulated using a vibration platform combined with inclination angle adjustment to mimic uneven road conditions. The sensor array is placed in key areas of the sole, such as the forefoot and heel, to collect pressure data in real time.

[0101] It should be noted that the stress distribution dataset is generated by these sensors, including peak stress and average stress values for each region, and the data is stored in a matrix form for subsequent analysis. This simulation ensures that the test is close to the real use environment, improving the reliability of the data.

[0102] Specifically, the process of obtaining the stress distribution dataset involves data collection and preliminary processing. During the test, the sensor records time series data, such as high stress points detected in the forefoot area, which may be caused by rapid turning movements.

[0103] In one embodiment, a filtering algorithm is used to remove noise and ensure the accuracy of the dataset.

[0104] Preferably, in a basketball simulation, the jump load is increased, and the dataset shows stress concentration in the middle of the sole, thus revealing potential fatigue points. The principle of this process is that the stress distribution reflects the mechanical response inside the material, and by comparing data from different scenarios, the weak areas of the sole can be identified. Based on the obtained dataset, the overall stability level of the sole assembly is determined. Further, the analysis step includes calculating a stability index, such as a stress uniformity coefficient, which is derived from the ratio of the standard deviation to the average value of the dataset.

[0105] For example, if the standard deviation is less than 10% of the average value, it is considered to be a high stability level.

[0106] In one embodiment, for a hiking shoe scenario, the rugged terrain load is simulated, and the dataset shows that the reinforced material reduces stress peaks and improves overall stability. This determination method helps to optimize the sole design and achieve better durability. In another implementation, for casual shoe applications, the test simulates a daily walking scenario with light but long-lasting loads. The dataset focuses on long-term fatigue stress, and the stability evaluation shows that the reinforced assembly can maintain uniform distribution and reduce the risk of deformation.

[0107] Exemplarily, this approach is extended to running shoes combined with high-speed simulation, demonstrating the universality of the technical solution in the footwear field.

[0108] It can be understood that through the above test and analysis, the stability level of the sole assembly is objectively evaluated, supporting further material improvement.

[0109] In a possible implementation, the integrated software tool visualizes the stress distribution map, facilitating engineers to interpret the data and achieve efficient optimization.

[0110] Step S108, by comparing the overall stability level with the preset standard, if the overall stability level meets the requirements, the final product is manufactured by batch production process to obtain the sports sole meeting the accurate layout.

[0111] If the stability comparison result meets the requirements, the batch production process is adopted to obtain manufacturing parameters from the stability comparison result, the production setting is adjusted through the manufacturing parameters, the final product layout is determined, and the sports sole meeting the accurate layout is obtained.

[0112] Specifically, in an embodiment, the overall stability level of the sports sole is evaluated, which generally refers to the deformation resistance and structural integrity of the sole material under stress, for example, by testing the bending and twisting performance of the sole under simulated walking conditions.

[0113] It should be noted that the overall stability level can be calculated based on the measured parameters such as hardness value and elastic modulus, ensuring that the sole will not easily deform in actual use, thereby supporting the design requirements of accurate layout. Further, the overall stability level is compared with the preset standard, which can be a threshold value defined in industry specifications, for example, the stability level needs to reach more than 80% to meet the durability requirements.

[0114] Specifically, the comparison process involves matching the calculated stability level value with the standard threshold value one by one, if the value is higher than the threshold value, it is determined to meet the requirements. This comparison helps to screen out high-quality sole prototypes and avoid producing inferior products.

[0115] In a possible implementation, if the overall stability level meets the requirements, the final product is manufactured by batch production process. The batch production process includes injection molding and assembly steps, for example, the sole mold meeting the standard is first placed in the production line, the material is injected and cooled to form by automatic setting, and the sports sole meeting the accurate layout is obtained.

[0116] Preferably, such a process can integrate a quality monitoring system to ensure the consistency of each batch of products.

[0117] It can be understood that in the mass production of sports shoe soles, precise layout refers to the accurate positioning of sole patterns and support structures, such as ensuring uniform distribution of anti-slip textures through CAD design. This implementation is not only applicable to running shoe soles, but also extends to basketball shoe sole scenarios, demonstrating the universality of the technical solution.

[0118] In one embodiment, if the stability level does not meet the requirements, the optimized prototype design can be returned, such as adjusting the material ratio to improve stability, and then re-evaluating. This cyclic process enhances the flexibility of production and avoids waste of resources.

[0119] Specifically, after mass production, the final product can be sampled and tested, such as testing the stability of the sole at different temperatures, to verify the effect of precise layout. In this way, efficient manufacturing and product quality maintenance can be achieved. Further, in another embodiment, the preset standard can be dynamically adjusted according to the type of sole, such as setting a higher stability threshold for trail shoe soles to adapt to complex terrain. This adjustment is achieved through software tools, supporting various production scenarios.

[0120] For example, in actual operation, the calculation of overall stability level can refer to the geometric parameters of the sole, such as thickness uniformity and edge strength, and directly trigger production instructions based on the comparison results, thereby obtaining a layout-precise sports shoe sole.

[0121] It should be noted that this technical solution provides reliable support in the field of sole manufacturing, ensuring logical coherence from evaluation to production, and ultimately meeting user demands for durability and comfort.

[0122] Although the present application has been described in detail above with general description and specific embodiments, some modifications or improvements can be made on the basis of the present application, which is obvious to those skilled in the art. Therefore, these modifications or improvements made on the basis of not deviating from the spirit of the present application, all belong to the scope of protection required by the present application.

Claims

1. A seamless integrated molding method for silicone nodes and shoe soles, characterized in that, The method includes the following steps: Step S101: Collect basic structural data of the shoe sole using a digital scanning device. The basic structural data includes the shoe sole outline and surface details. Use 3D modeling technology to process the point cloud information in the basic structural data to obtain a 3D geometric model of the shoe sole. Step S101 includes: The basic structural data of the shoe sole is collected by a digital scanning device. The basic structural data includes the shoe sole outline and surface details. The point cloud information in the basic structural data is processed by three-dimensional modeling technology. The three-dimensional modeling technology generates a surface mesh by meshing the point cloud to obtain a three-dimensional geometric model of the shoe sole. Based on the three-dimensional geometric model of the shoe sole, material distribution characteristics are extracted from the model, and the material distribution characteristics are processed by the finite element analysis method. The finite element analysis method calculates the stress value by dividing the mesh elements and applying loads to obtain the stress distribution map of the shoe sole. By using the stress distribution map of the sole, the thickness data of the abrasion layer of the sole is obtained for the high stress area in the distribution map. It is then determined whether the thickness data is lower than a preset threshold. If it is lower than the preset threshold, the thickness parameter of the high stress area is adjusted to obtain the optimized sole structure parameters. Based on the optimized sole structure parameters and the three-dimensional geometric model of the sole, customized production data for the sole is generated. This production data is used to determine the final three-dimensional geometric model of the sole. Step S102: Surface curvature features are extracted from the three-dimensional geometric model of the sole. These curvature features reflect the bending shape and pressure distribution area of ​​the sole. Simulation analysis technology is used to determine the initial distribution scheme of the silicone nodes. The silicone nodes are silicone material embedding points used to provide foot support and impact cushioning. Step S103: If the node spacing deviation in the initial distribution scheme exceeds a preset threshold, the coordinate parameters of the silicone nodes are adjusted using optimization calculation technology. This adjustment comprehensively considers the overall balance of the sole, resulting in an optimized node position configuration. Step S104: A silicone material injection path is generated for the optimized node position configuration. This injection path ensures uniform material distribution. Additive manufacturing technology is used to construct an integrated molding die to obtain a sole prototype containing embedded nodes. Step S105: Extract the interface data of the nodes and the sole from the prototype sole. The interface data includes the texture of the contact surface and the features of the connection points. Image analysis technology is used to evaluate the continuity of the interface and determine the bonding strength index. Step S106: If the bonding strength index is lower than a preset threshold, the structure of the prototype sole is modified by hot-pressing fusion technology to obtain an enhanced sole component. Step S107: Perform dynamic load testing on the enhanced sole component. The test simulates a motion scenario to obtain a stress distribution dataset and determine the overall stability level of the sole component. Step S108: Compare the overall stability level with a preset standard. If the overall stability level meets the requirements, mass production process is used to manufacture the final product to obtain a sports sole that meets the precise layout requirements.

2. The seamless integrated molding method for silicone nodes and shoe soles according to claim 1, characterized in that, Step S102 includes: By using the aforementioned shoe sole geometric model, the surface curvature characteristics are obtained, and the bending shape is reflected. Based on the bending morphology, finite element analysis is used, in which the pressure distribution region is determined by meshing and calculating the stress distribution. For the pressure distribution area, simulation analysis technology is used, wherein the simulation analysis technology calculates the node positions through load simulation to obtain the distribution of silicone nodes; Based on the distribution of the silicone nodes, a mesh optimization method is adopted, in which the initial scheme is determined by adjusting the node density to obtain the silicone material locations.

3. The seamless integrated molding method for silicone nodes and shoe soles according to claim 1, characterized in that, Step S103 includes: By scanning the surface of the shoe sole, the initial coordinates of the silicone nodes are obtained, and the node spacing deviation value is determined. If the node spacing deviation exceeds a preset threshold, a gradient descent algorithm is used with the silicone node coordinates as input to adjust the coordinate parameters and obtain preliminary adjustment coordinates. Based on the initial coordinate adjustment, the pressure distribution mapping of the sole is calculated, and the overall balance index is judged by comparing the mapping value with the balance threshold. By refining the coordinates of the silicone nodes using the overall balance index, an optimized node position configuration is obtained.

4. A seamless integrated molding method for silicone nodes and shoe soles according to any one of claims 1-3, characterized in that, Step S104 includes: By configuring node positions, the silicone injection path is obtained from node strength verification to ensure uniform material distribution. Based on the silicone injection path, an integrated molding die is constructed using additive manufacturing to ensure uniform path distribution. If the material is evenly distributed in the integrated molding mold, the embedded node settings are obtained through prototype density analysis to determine the generation of the shoe sole prototype; For the embedded node settings, manufacturing path optimization is obtained from mold material fusion to determine the node strength verification; By optimizing the manufacturing path and integrating the path uniformity guarantee with the prototype density analysis, a shoe sole prototype containing embedded nodes is obtained.

5. A seamless integrated molding method for silicone nodes and shoe soles according to any one of claims 1-3, characterized in that, Step S105 includes: Data on the interface between nodes and the sole is obtained from the prototype sole. The texture of the contact surface and the features of the connection points are extracted by the edge detection algorithm to obtain the interface continuity index. For the interface continuity index, optical flow analysis is used to evaluate the interface uniformity and determine the continuity score. Based on the continuity score, if the score is lower than a preset threshold, the node position parameters are adjusted to obtain optimized interface data. By comparing the connection point features and texture changes using the optimized interface data, the bonding strength index is determined.

6. A seamless integrated molding method for silicone nodes and shoe soles according to any one of claims 1-3, characterized in that, Step S106 includes: The surface data of the shoe sole prototype is obtained by scanning equipment, and the bonding point density and material uniformity are extracted from the surface data to calculate the bonding strength index. If the bonding strength index is lower than the preset threshold, hot-press fusion technology is used to apply uniform pressure and temperature to the prototype structure, and the fusion parameters are adjusted to correct the weak areas, resulting in a reinforced sole component.

7. A seamless integrated molding method for silicone nodes and shoe soles according to any one of claims 1-3, characterized in that, Step S107 includes: Initial load data is obtained by constructing a motion scenario. Stress distribution collection points are determined for the dynamic load simulation to obtain a preliminary dataset. Data noise is filtered using the preliminary dataset, and the purified distribution is obtained from the stress distribution collection. The load peak identification result is judged. The scene parameters are adjusted according to the purified distribution. The distribution dataset is fused for the load peak identification to obtain an enhanced verification index. The index correlation is calculated through the enhanced verification index. The overall stability level is judged based on the stability threshold setting to obtain the durability assessment of the sole component.

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