Skin-touch vamp and manufacturing method thereof

Abstract

The invention discloses a skin-touch vamp and a manufacturing method thereof, and relates to the technical field of shoe material manufacturing, and the manufacturing method comprises the following steps: providing a vamp base material and skin-touch slurry containing nanoscale powder; performing three-dimensional scanning on the vamp base material, and setting differential jet printing parameters for jet printing equipment; spraying the skin feeling slurry on a vamp base material to form a wet film coating; before the wet film coating is cured, measuring the thickness distribution of the coating according to a scanning signal; and according to the measured thickness distribution, the jet printing equipment is controlled to only carry out secondary spraying on the areas. According to the method, the uneven curved surface coating is inhibited from the source through three-dimensional scanning and self-adaptive parameter setting, the thickness distribution of the wet film is obtained in real time and in a lossless mode through the hyperspectral on-line thickness measurement technology, fixed-proportion accurate compensation spraying is carried out on the substandard area, a closed loop is manufactured through real-time detection and instant deviation correction, and the production efficiency is improved. And a high-quality skin-touch coating with uniform thickness and touch height is obtained on a complex three-dimensional vamp, so that the product yield and the process stability are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of footwear material manufacturing technology, and in particular to a skin-feeling shoe upper and its manufacturing method. Background Technology

[0002] In the footwear manufacturing industry, giving shoe uppers a delicate and skin-friendly "skin feel" has become an important direction for increasing product added value. Currently, the industry mainly achieves this skin-feel effect by coating or printing special pastes onto the shoe upper substrate. However, existing production processes still face a series of technical bottlenecks: First, for shoe uppers with complex three-dimensional curved surfaces, traditional fixed-parameter spraying or printing processes cannot dynamically adjust the construction parameters according to the curvature of the surface, resulting in the coating easily piling up or becoming too thin in high-curvature areas, while failing to achieve the expected fullness in flat areas, leading to poor overall uniformity; second, the production process lacks... Real-time, quantitative, and non-destructive online detection of coating thickness in the wet film state relies heavily on manual judgment after curing for quality control, making it impossible to detect and locate micro-thickness defects in advance. Furthermore, the entire process is mostly open-loop controlled, and even if uneven thickness is detected, it is impossible to perform precise local compensation processing on the product in real time, resulting in low product consistency and high scrap rate. Therefore, developing a manufacturing method for shoe upper skin-feel coatings that can intelligently adapt to surface changes, perform real-time online detection, and provide immediate closed-loop compensation is of great significance for improving product quality and production efficiency.

[0003] However, current common solutions have many drawbacks, including: the manufacturing process of existing technologies has significant limitations: they use fixed construction parameters, which cannot adapt to the complex three-dimensional curved surface changes of shoe uppers, resulting in poor coating uniformity; they lack real-time online thickness detection of the wet film state, and the quality depends on human experience judgment after curing; the production process is an open-loop control, which cannot locate and compensate for defects in real time; and the process parameter settings depend on human experience, making it difficult to achieve data-driven continuous optimization, resulting in low product consistency and unstable yield. Summary of the Invention

[0004] The purpose of this section is to outline some aspects of embodiments of the present invention and to briefly describe some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, to avoid obscuring the purpose of these documents; however, such simplifications or omissions should not be construed as limiting the scope of the invention.

[0005] In view of the problems existing in the current skin-feel shoe upper and its manufacturing method, the present invention is proposed.

[0006] Therefore, the purpose of this invention is to provide a skin-feel shoe upper and its manufacturing method, which is applicable to solving the problems of existing technologies that mainly adopt static, open-loop production modes that rely on manual experience. When faced with complex three-dimensional shoe uppers, the printing process with fixed parameters is difficult to guarantee the uniformity of the coating. At the same time, due to the lack of real-time online detection capabilities for key micro-parameters such as coating thickness and density, the production process cannot be corrected and optimized in a timely manner, resulting in poor product consistency, high defect rate, and difficulty in achieving efficient and stable manufacturing of high-quality skin-feel shoe uppers.

[0007] To solve the above-mentioned technical problems, the present invention provides the following technical solution:

[0008] In a first aspect, embodiments of the present invention provide a method for manufacturing a skin-feeling shoe upper, comprising: Step 1: Raw material preparation step: providing a shoe upper substrate and a skin-feeling slurry containing nano-scale powder; Step 2: Scanning and adaptive parameter setting: performing a three-dimensional scan on the shoe upper substrate, and setting differentiated printing parameters that vary with position for the printing equipment based on the surface curvature changes, so that the printing parameters automatically adapt to the three-dimensional shape of the shoe upper; Step 3: Initial printing: using the printing equipment, the skin-feeling slurry is sprayed onto the shoe upper substrate according to the differentiated parameters set in Step 2 to form a wet film coating; Step 4: Online thickness measurement: before the wet film coating cures, it is immediately scanned using a hyperspectral imager, and the thickness distribution of the coating is measured based on the scanning signal; Step 5: Compensation printing: based on the thickness distribution measured in Step 4, areas with insufficient thickness are located, and the printing equipment is controlled to perform secondary printing only on these areas.

[0009] In a preferred embodiment of the manufacturing method of the skin-feel shoe upper described in this invention, the setting of differentiated printing parameters that vary with position specifically involves setting a combination of printing flow rate and printhead movement speed based on the surface curvature obtained from the three-dimensional scan.

[0010] As a preferred embodiment of the manufacturing method of the skin-feel shoe upper described in this invention, the step of scanning the wet film coating with a hyperspectral detector specifically involves using a hyperspectral imaging system to perform line scanning or surface scanning on the wet film coating after the printing station and before the curing process to obtain its reflectance spectral data at different wavelengths.

[0011] In a preferred embodiment of the manufacturing method of the skin-feel shoe upper described in this invention, the thickness distribution of the coating is measured based on the scanning signal by comparing and analyzing the reflectance spectral data with a pre-established database or model that characterizes the correspondence between spectral features and coating thickness.

[0012] In a preferred embodiment of the manufacturing method of the skin-feel shoe upper described in this invention, the amount of slurry deposited in the secondary spraying is 30% to 70% of the amount deposited in the first spraying in step three for the corresponding area.

[0013] As a preferred embodiment of the manufacturing method of the skin-feel shoe upper described in this invention, the differential parameters in step three are optimized by iteratively optimizing the rules for setting differential parameters according to curvature changes in step two based on the thickness distribution data and corresponding printing parameters obtained in multiple shoe upper production processes.

[0014] In a preferred embodiment of the manufacturing method of the skin-feel shoe upper described in this invention, the nano-sized powder is silicon dioxide, zinc oxide, or titanium dioxide powder with an average particle size between 20 nanometers and 100 nanometers.

[0015] In a preferred embodiment of the manufacturing method of the skin-feel shoe upper described in this invention, the printing equipment is a piezoelectric inkjet industrial printer or a micro-droplet ejection valve system.

[0016] As a preferred embodiment of the manufacturing method of the skin-feel shoe upper described in this invention, after the compensation printing is completed, the method further includes a step of drying or photocuring the wet film coating to form the final solid skin-feel layer.

[0017] Secondly, to further solve the above-mentioned technical problems, the present invention provides a skin-feeling shoe upper, characterized in that it is manufactured by the manufacturing method of any one of claims 1 to 9.

[0018] The beneficial effects of this invention are as follows: This invention suppresses uneven coating on curved surfaces at the source through three-dimensional scanning and adaptive parameter setting, and utilizes hyperspectral online thickness measurement technology to obtain the wet film thickness distribution in real time and non-destructively. This allows for precise proportional compensation spraying of substandard areas, achieving a manufacturing closed loop of "real-time detection - immediate correction." Simultaneously, the system can accumulate production data and iteratively optimize adaptive rules. Ultimately, this method ensures a high-quality, skin-feel coating with uniform thickness and tactile feel on complex three-dimensional shoe surfaces, significantly improving product yield and process stability. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein:

[0020] Figure 1 This is a flowchart illustrating the implementation of the present invention in Example 1. Detailed Implementation

[0021] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0022] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0023] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0024] Example 1

[0025] Reference Figure 1 This is the first embodiment of the present invention, which provides a skin-feeling shoe upper and a method for manufacturing the same, including the following steps:

[0026] S1: Raw material preparation steps: Provide shoe upper base material and skin-feel slurry containing nano-level powder.

[0027] Specifically, nanoscale powders are silicon dioxide, zinc oxide, or titanium dioxide powders with an average particle size between 20 nanometers and 100 nanometers.

[0028] Furthermore, the nanoscale powder is silica, zinc oxide, or titanium dioxide powder with an average particle size between 20 nanometers and 100 nanometers.

[0029] It should be noted that the skin-feeling paste is prepared as follows:

[0030] Nanoparticles: Spherical fumed silica powder with an average particle size D50 of 50 nm and a particle size distribution D90 ≤ 80 nm was selected. The powder was surface-treated with a silane coupling agent to improve its dispersibility and compatibility in the resin.

[0031] Slurry formulation: By weight percentage, mix 30% of the above-mentioned nano silica powder, 58% of waterborne acrylic-polyurethane hybrid resin, 1% of polyether modified polysiloxane leveling agent, 0.2% of mineral oil defoamer and 10.8% of deionized water.

[0032] Dispersion process: The mixture is initially mixed for 15 minutes at 800 rpm using a high-speed disperser, and then transferred to a basket mill for circulating grinding and dispersion for 60 minutes until the fineness of the slurry is ≤10μm.

[0033] Performance indicators: The viscosity of the prepared slurry at 25℃ is 320±30mPa·s, the pH value is 8.0±0.5, and the solid content is 40%±1%.

[0034] Preferably, by precisely designing the slurry formulation and dispersion process containing specific nanoparticles (such as surface-treated spherical silica), a controllable physicochemical foundation is laid for subsequent precision manufacturing. This not only ensures that the slurry has rheological properties (such as viscosity and stability) suitable for dynamic printing, but more importantly, the uniform dispersion and specific particle size distribution of the nanoparticles are the core material guarantee for ultimately obtaining a delicate and smooth "skin-like" tactile feel, determining the high-end texture of the product from the source.

[0035] For example, to produce a flyknit upper for a sports shoe, the substrate is first cleaned, and then a skin-feel slurry is prepared: 40-nanometer spherical silica powder (accounting for 28% of the total weight) with a surface treated with silane is taken and mixed with water-based polyurethane resin (accounting for 65%), leveling agent and defoamer. The mixture is then processed for 90 minutes using a high-speed dispersion combined with sand milling process to finally obtain a slurry with a viscosity of about 280 mPa·s, a solid content of about 38% and uniform dispersion of nanoparticles, providing a stable and suitable material basis for subsequent precision printing.

[0036] S2: Scanning and Adaptive Parameter Setting: Perform a three-dimensional scan of the shoe upper substrate and set differentiated printing parameters for the printing equipment based on the changes in its surface curvature, so that the printing parameters automatically adapt to the three-dimensional shape of the shoe upper.

[0037] Specifically, differentiated printing parameters that vary with location are set: based on the surface curvature obtained from 3D scanning, a combination of printing flow rate and printhead movement speed is set accordingly; for areas with large curvature, a relatively small printing flow rate and a relatively large printhead movement speed are used; for areas with small curvature, a relatively large printing flow rate and a relatively small printhead movement speed are used.

[0038] Furthermore, the shoe upper substrate is precisely clamped into a scanning station equipped with a six-degree-of-freedom robot. A blue light 3D structured light scanner is used to scan the shoe upper with a dot pitch resolution of 0.05mm to obtain a high-precision triangular mesh surface model.

[0039] Specifically, the thickness distribution of the coating is measured based on the scanning signal by comparing and analyzing the reflectance spectral data with a pre-established database or model that characterizes the relationship between spectral features and coating thickness.

[0040] Preferably, intelligent feedforward decision-making from "geometric shape perception" to "physical deposition strategy generation" is realized. By establishing dynamic mapping rules between curvature and printing parameters (flow rate, speed), this step essentially transforms complex fluid dynamics experience into an executable digital process model. This allows for pre-compensation of coating inhomogeneity caused by surface changes before processing, providing key pre-defined optimization for obtaining uniform coatings on complex three-dimensional substrates.

[0041] For example, a point cloud model is obtained through 3D structured light scanning, and the local curvature distribution is calculated. Based on preset rules, the system automatically selects the most convex part of the toe (curvature approximately 0.12mm). -1 The system is designed as a "low flow rate - high speed" mode (e.g., flow rate 8 ml / min, speed 140 mm / s), while the adjacent relatively flat lateral regions (curvature approximately 0.01 mm) are... -1 The system is designed as a "high flow rate - slow speed" mode (e.g., flow rate 22ml / min, speed 50mm / s), and parameters are interpolated for the remaining transition areas to generate a complete adaptive inkjet control file.

[0042] S3: First printing: Using printing equipment, the skin-feel paste is sprayed onto the shoe upper substrate according to the differentiated parameters set in step two to form a wet film coating.

[0043] Furthermore, the printing equipment is a piezoelectric inkjet industrial printer or a micro-droplet ejection valve system.

[0044] Preferably, the differential parameters in step three are optimized by iteratively optimizing the rules for setting differential parameters based on curvature changes in step two, based on the thickness distribution data and corresponding printing parameters obtained in multiple shoe upper production processes.

[0045] Preferably, the prepared nano-textured paste is loaded into a precision inkjet printing device, which preferably employs on-demand dripping technology. The system loads the digital control instruction set generated in step S2, controls the printhead to move along a predetermined path above the shoe upper substrate, and dynamically adjusts the printing flow rate and printhead movement speed in real time according to the instructions. Through this adaptive inkjet printing process, a continuous and uniform wet coating is formed on the shoe upper surface.

[0046] Preferably, the differentiated digital instructions generated in step S2 are converted into actual material distribution. By executing the dynamic parameters in real time through a high-response nozzle, this step ensures that the nano-slurry can achieve differentiated and precise deposition in the high-curvature and low-curvature areas of the shoe surface, thereby transforming the previous intelligent planning into a uniform wet film coating entity in a non-destructive and efficient manner.

[0047] For example, the prepared slurry is loaded into the piezoelectric inkjet equipment and the control file is loaded. When the printhead moves to the high curvature position of the shoe toe, it automatically switches to low flow and high speed mode for printing. When it moves to a flat area, it switches to high flow and low speed mode. By automatically executing this position-varying parameter throughout the process, a generally uniform and uncured wet film coating is formed on the shoe surface, initially achieving differentiated and precise deposition on curved surfaces.

[0048] S4: Online thickness measurement: Before the wet film coating cures, it is immediately scanned with a hyperspectral analyzer, and the thickness distribution of the coating is measured based on the scanning signal.

[0049] Preferably, a hyperspectral analyzer is used to scan it. Specifically, after the printing station and before the curing process, a hyperspectral imaging system is used to perform line scanning or surface scanning on the wet film coating to obtain its reflectance spectral data at different wavelengths.

[0050] Furthermore, within the critical time window before the wet film coating has cured, an online hyperspectral detection device is immediately used to rapidly scan its surface, collecting optical response signals (reflectance spectral data) of the coating at multiple characteristic wavelengths. A knowledge model or database, established through experimental calibration, is pre-stored to characterize the correspondence between spectral features and wet film coating thickness. By comparing and analyzing the real-time acquired spectral data with the knowledge model or database, the thickness value of the wet film coating at various locations on the shoe surface is calculated in real time, thereby generating a complete coating thickness distribution map.

[0051] Preferably, it achieves real-time, non-destructive, and full-field quantitative perception of the core quality indicator (thickness) of the coating during the production process. By utilizing hyperspectral technology and combining it with a pre-calibrated model, this step can quickly obtain a spatial thickness distribution map during the critical window period before the wet film cures. This overcomes the lag and one-sided limitations of traditional methods that rely on sampling or destructive testing after curing, equipping the manufacturing process with "X-ray vision" and providing the only reliable data input for real-time quality control and closed-loop feedback.

[0052] For example, in the wet film state after printing, the hyperspectral imager quickly scans the shoe surface and performs real-time matching analysis with the collected reflectance spectrum data and a "spectral feature-thickness" database established in advance through a large number of standard samples. The analysis results show that the thickness of most areas of the shoe surface is between 18 and 22 micrometers, but a local spectral feature is abnormal at the edge of the toe, which shows that its thickness is only 12 micrometers, thus accurately locating the weak area that needs subsequent compensation.

[0053] S5: Compensation Printing: Based on the thickness distribution measured in step four, locate the areas with insufficient thickness and control the printing equipment to perform secondary spraying only on these areas.

[0054] Preferably, the amount of slurry deposited in the second spraying is 30% to 70% of the amount deposited in the first spraying in step three for the corresponding area.

[0055] It should be noted that by comparing the real-time thickness distribution map obtained in step S4 with the preset qualified thickness standard, the system automatically identifies and locates the areas where the thickness is lower than the standard (i.e., weak areas). For these specific weak areas, a local compensation printing path is planned, and the printing equipment is controlled to perform a precise secondary spraying with a paste deposition rate lower than that of the first printing in that area. The purpose of the compensation spraying is to supplement the material only in the defective parts so that their thickness reaches the qualified range without affecting the areas that have already met the standard.

[0056] Preferably, after the compensation printing is completed, the wet film coating is cured (e.g., by hot air drying or ultraviolet light irradiation) to transform it into a firm, dry solid coating with stable skin-feel properties. Furthermore, this method includes a process optimization cycle: the system continuously collects and stores key data from the production process of each product, including three-dimensional morphology, printing parameters, measured thickness distribution, and compensation records. Statistical analysis of this historical data can identify potential systematic deviations in the original adaptive parameter setting rules, and based on this, the rules can be automatically or manually iteratively optimized and calibrated, thereby enabling the entire manufacturing process to continuously improve itself.

[0057] Preferably, based on the real-time data from step S4, a rapid online closed loop of "perception-execution" is constructed. By locating areas with insufficient thickness and performing local secondary spraying at a certain ratio, this step can perform in-situ and precise micro-correction for random defects or deviations that cannot be fully compensated by feedforward. This significantly improves the first-pass yield of a single product and transforms the traditional "open-loop" production mode into a "closed-loop" intelligent process with real-time self-correction capabilities.

[0058] For example, for areas with insufficient thickness identified by online thickness measurement (such as 12 micrometers in the previous example), the system generates a micro-re-spray path that only covers the area. The printing equipment is controlled to perform a rapid, localized secondary spraying at 50% of the initial spraying flow rate (i.e., 4 ml / min) on the specific location. After the re-spraying, the thickness at that point increases to about 17 micrometers, which is within the acceptable range, while the surrounding areas that have already met the standards are not affected in any way.

[0059] In summary, this invention suppresses uneven coating on curved surfaces at the source through 3D scanning and adaptive parameter setting. It also utilizes hyperspectral online thickness measurement technology to obtain the wet film thickness distribution in real time and non-destructively, enabling precise proportional compensation spraying for substandard areas, thus achieving a closed-loop manufacturing process of "real-time detection and immediate correction." Simultaneously, the system accumulates production data and iteratively optimizes adaptive rules. Ultimately, this method ensures a high-quality, skin-feel coating with uniform thickness and tactile feel on complex 3D shoe surfaces, significantly improving product yield and process stability.

Claims

1. A method for manufacturing a skin-feel shoe upper, characterized in that: include: Step 1: Raw Material Preparation: Provide the shoe upper base material and the skin-feeling slurry containing nano-sized powders; Step 2: Scanning and Adaptive Parameter Setting: Perform a three-dimensional scan on the shoe upper substrate, and set differentiated printing parameters for the printing equipment based on the changes in its surface curvature, so that the printing parameters automatically adapt to the three-dimensional shape of the shoe upper. Step 3: Initial printing: Using printing equipment, the skin-feel paste is sprayed onto the shoe upper substrate according to the differential parameters set in Step 2 to form a wet film coating. Step 4: Online thickness measurement: Before the wet film coating cures, it is immediately scanned with a hyperspectral analyzer, and the thickness distribution of the coating is measured based on the scanning signal; Step 5: Compensation Printing: Based on the thickness distribution measured in Step 4, locate the areas with insufficient thickness, and control the printing equipment to perform secondary spraying only on these areas.

2. The method for manufacturing a skin-feel shoe upper as described in claim 1, characterized in that: The setting of differentiated printing parameters that vary with position is specifically: based on the surface curvature obtained from the three-dimensional scan, a combination of printing flow rate and printhead movement speed is set accordingly.

3. The method for manufacturing a skin-feel shoe upper as described in claim 1, characterized in that: The scanning of the wet film coating using a hyperspectral detector specifically involves using a hyperspectral imaging system to perform line or surface scanning after the printing station and before the curing process to obtain its reflectance spectral data at different wavelengths.

4. The method for manufacturing a skin-feel shoe upper as described in claim 3, characterized in that: The thickness distribution of the coating is measured based on the scanning signal by comparing and analyzing the reflectance spectral data with a pre-established database or model that characterizes the relationship between spectral features and coating thickness.

5. The method for manufacturing a skin-feel shoe upper as described in claim 1, characterized in that: The amount of slurry deposited in the secondary spraying is 30% to 70% of the amount deposited in the first spraying in step three for the corresponding area.

6. The method for manufacturing a skin-feel shoe upper as described in claim 1, characterized in that: The differential parameters described in step three are optimized by iteratively optimizing the rules for setting differential parameters based on curvature changes in step two, based on the thickness distribution data and corresponding printing parameters obtained in multiple shoe upper production processes.

7. The method for manufacturing a skin-feel shoe upper as described in claim 1, characterized in that: The nanoscale powder is silicon dioxide, zinc oxide, or titanium dioxide powder with an average particle size between 20 nanometers and 100 nanometers.

8. The method for manufacturing a skin-feel shoe upper as described in claim 1, characterized in that: The printing equipment is a piezoelectric inkjet industrial printer or a micro-droplet ejection valve system.

9. The method for manufacturing a skin-feel shoe upper as described in claim 1, characterized in that: After the compensation printing is completed, the process also includes drying or photocuring the wet film coating to form the final solid skin-feel layer.

10. A skin-feel shoe upper, characterized in that, It is obtained by the manufacturing method of a skin-feel shoe upper as described in any one of claims 1 to 9.

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