A breathable and moisture-wicking shoe upper structure

Abstract

This invention relates to the field of footwear technology, specifically to a breathable and moisture-wicking shoe upper structure, comprising, from the outside to the inside, a wear-resistant and breathable outer layer, a zoned flow-guiding and cushioning layer, a one-way breathable membrane layer, a gradient moisture-wicking lining layer, and a foot-fitting elastic padding layer. The wear-resistant and breathable outer layer, zoned flow-guiding and cushioning layer, one-way breathable membrane layer, gradient moisture-wicking lining layer, and foot-fitting elastic padding layer are compositely formed using zoned dotted breathable adhesives. The structure formed by these components is divided according to the pressure and sweat distribution of the human foot into a high-heat breathable zone in the forefoot, a torsional support zone in the arch, a heel wrapping buffer zone, and a main breathable zone in the middle of the instep. This invention has the following beneficial effects: it solves multiple defects of traditional shoe uppers, such as the inability to simultaneously achieve breathability and support, sweat backflow, rainwater intrusion, blockage of breathable pores by interlayer adhesives, and localized hot and stuffy corners.

Description

Technical Field

[0001] This invention relates to the field of shoemaking technology, specifically to a breathable and moisture-wicking shoe upper structure. Background Technology

[0002] Currently, breathable and moisture-wicking shoe uppers on the market are mainly divided into three categories: single-layer flyknit mesh uppers, single-layer microporous membrane uppers, and simple two-layer composite uppers. Traditional breathable uppers use a uniform mesh or microporous membrane structure throughout, completely ignoring the different stress points on the instep, forefoot, arch, and heel. The forefoot, arch, and heel areas require rigid support, and large areas of breathable mesh will reduce lateral tear resistance, making them prone to loosening and deformation after bending during exercise. If TPU hot-melt adhesive reinforcement is added to the stress areas, the adhesive film will completely block the breathable channels, creating localized hot and humid dead zones. Sweat and humid air cannot dissipate, and after prolonged walking, socks become heavily soaked, fostering fungal growth and inducing skin problems such as athlete's foot and eczema. Ordinary uppers lack zoned gradient breathability design, resulting in insufficient breathability in high-heat, sweat-prone areas and redundant breathability in low-temperature stress areas, leading to low overall heat and moisture exchange efficiency and failing to create a stable micro-circulation of air inside the shoe. Summary of the Invention

[0003] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a breathable and moisture-wicking shoe upper structure to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a breathable and moisture-wicking shoe upper structure, comprising, from the outside to the inside, a wear-resistant and breathable outer layer, a zoned drainage and cushioning layer, a one-way moisture-wicking functional membrane layer, a gradient moisture-absorbing and wicking inner lining layer, and a foot-fitting elastic padding layer. The wear-resistant and breathable outer layer, the zoned drainage and cushioning layer, the one-way moisture-wicking functional membrane layer, the gradient moisture-absorbing and wicking inner lining layer, and the foot-fitting elastic padding layer are compositely formed using zoned dotted breathable adhesives. The diameter of the adhesive dots is controlled between 0.8mm and 1.5mm, and the center-to-center distance between adjacent adhesive dots is 3mm to 6mm, achieving localized point adhesion. Next, at least 90% of the continuous breathable channels are retained to avoid the defects of the entire rubber layer blocking micropores. The structure formed by the wear-resistant and breathable outer layer, the zoned flow-guiding buffer layer, the one-way moisture-permeable functional membrane layer, the gradient moisture-absorbing and moisture-wicking inner lining layer, and the foot-shaped elastic pad layer is divided into a forefoot high-heat breathable zone, an arch torsional support zone, a heel wrapping buffer zone, and a mid-instep main breathable zone according to the human foot's pressure and sweat distribution. The porosity, membrane pore size, yarn density, and elastic modulus of the forefoot high-heat breathable zone, arch torsional support zone, heel wrapping buffer zone, and mid-instep main breathable zone are configured with different gradients. Through the five-layer gradient layering and the four major foot-zone differentiated material design, the multiple defects of traditional shoe uppers, such as the inability to balance breathability and support, sweat backflow, rainwater backflow, interlayer rubber blocking of breathable pores, and localized stuffy dead corners, are solved.

[0005] Specifically, the wear-resistant and breathable outer layer of the main breathable area in the middle of the instep and the high-heat breathable area in the forefoot uses a large-pore three-dimensional flyknitted mesh fabric with an equivalent diameter of 1.2mm to 2mm and a porosity of 65% to 75%. The one-way breathable membrane layer uses a modified polytetrafluoroethylene hydrophobic microporous membrane with a pore size of 0.2μm to 0.4μm, allowing water vapor to penetrate only from the inside of the shoe to the outside, and preventing external liquid rainwater from seeping in the opposite direction. The wear-resistant and breathable outer layer of the arch torsional support area uses a high-low density alternating jacquard weave structure, with high-density woven strips along the arch. The high-density woven strips, 8mm-12mm wide, are continuously arranged and embedded with ultra-fine high-elastic polyester multifilaments to enhance lateral tear resistance. Continuous, long, breathable channels, 4mm-6mm wide, are reserved between the high-density woven strips to balance support rigidity and basic breathability. The heel wrap buffer zone features a thickened, partitioned flow-guiding layer. This layer is woven internally to form a honeycomb-like flow-guiding cavity, 0.5mm-1mm high, creating a convection channel for the circulation of hot and humid air inside the shoe, accelerating the outward movement of moisture from the sealed heel area. The gradient moisture-wicking lining layer is made of double-layer plain weave polyester yarn, with a highly absorbent, irregularly shaped cross-section yarn on the side closest to the skin and a low-absorbency, hydrophobic filament on the outside, forming a moisture-wicking gradient from the inside out to prevent backflow of sweat after saturation. The foot-shaped elastic padding layer is only placed at the contact points of the forefoot and heel, using open-pore high-elastic foam with breathable micropores inside to ensure air exchange between the upper and lower layers. The zoned air-guiding buffer layer is made of three-dimensional hollow elastic knitted fabric, with continuous air-guiding both longitudinally and laterally within the fabric. The grooves, precisely aligned with the micropores of the one-way breathable membrane and the mesh of the wear-resistant and breathable outer layer, form a continuous three-dimensional breathable pathway. Sweat generated by the feet inside the shoe cavity is first quickly absorbed by the gradient moisture-wicking lining, and then dispersed laterally to the entire shoe surface through the three-dimensional grooves of the zoned flow-guiding buffer layer. Subsequently, water vapor is discharged unidirectionally to the wear-resistant and breathable outer layer through the hydrophobic micropores of the one-way breathable membrane, and finally diffused to the outside air through the large-diameter mesh of the outer layer. At the same time, rainwater and water mist cannot penetrate the one-way breathable membrane and enter the shoe cavity in the opposite direction.

[0006] Specifically, the wear-resistant and breathable outer layer is made of modified polyester multifilament in a jacquard flyweave pattern. Before weaving, the polyester multifilament undergoes a hydrophobic and wear-resistant dual modification treatment. The modification process includes two steps: First, the polyester multifilament is immersed in a fluorinated hydrophobic emulsion with a mass fraction of 8%–12% for 25–35 minutes at room temperature. After removal, it is pre-dried at 110°C for 10 minutes to ensure that the fluorinated hydrophobic components uniformly coat the yarn surface, giving the yarn hydrophobic and stain-resistant properties and preventing outdoor dust and water stains from adsorbing and clogging the mesh. Second, a plasma surface bombardment treatment is performed with a bombardment power of 1200W–1600W for 40–60 seconds to form a micro-rough structure on the yarn surface, improving the adhesion to the zoned dotted breathable adhesive. This increases the surface's abrasion and friction coefficient, improving its resistance to pilling and scratching. The flyknit process employs differentiated weaving densities for the forefoot high-heat breathable zone, the arch torsional support zone, the heel wrap buffer zone, and the mid-instep main breathable zone. The mid-instep main breathable zone and the forefoot high-heat breathable zone use a three-up, three-down large-hole plain weave, with 12-18 mesh holes per square centimeter to ensure maximum breathability. The heel wrap buffer zone uses a double-layer flyknit structure, with a conventional hydrophobic mesh on the surface and an elastic fine denier woven lining on the bottom. A 0.3mm-0.6mm breathable gap is left between the two layers, connecting vertically to the honeycomb cavity of the lower zoned buffer layer to accelerate moisture removal from the enclosed heel space.

[0007] Specifically, after the wear-resistant and breathable outer layer is woven as a whole, it undergoes an overall shaping treatment. The shaping temperature is 130℃~140℃, the shaping pressure is 0.2MPa~0.3MPa, and the shaping time is 20min. During the shaping process, the internal stress of the weave is released by stretching simultaneously to prevent the finished product from shrinking and deforming after long-term use. After shaping, a matte wear-resistant and hydrophobic coating with a thickness of 3μm~6μm is roller-coated on the outer surface of the wear-resistant and breathable outer layer. The coating uses a water-based polyurethane wear-resistant base mixed with nano-silica wear-resistant powder and fluorine hydrophobic additive. After roller coating, it is dried and cured at a constant temperature of 70℃ for 15min. The coating only adheres to the surface of the yarn and will not block the breathable channels inside the mesh. It takes into account multiple effects such as weather resistance, UV resistance, abrasion resistance, hydrophobic self-cleaning, etc. Under long-term outdoor sunlight and friction conditions, the mesh is not easily blocked, and the hydrophobic performance decays by less than 8%.

[0008] Specifically, the partitioned flow-guiding buffer layer is an integral three-dimensional hollow knitted fabric, made of double-warp and double-weft elastic spandex multifilaments and conventional polyester hollow yarns. The knitted fabric has integrally formed longitudinal and transverse flow-guiding grooves. The longitudinal grooves are continuous along the upper and lower direction of the shoe upper, with a semi-circular cross-section, a groove depth of 0.4mm to 0.8mm, and a groove width of 1mm to 1.8mm. The transverse grooves are continuously arranged horizontally along the upper and lower side, and are perpendicularly connected to the longitudinal grooves to form a fully covered three-dimensional mesh flow-guiding channel. At the intersection of the grooves, an integrally formed honeycomb hollow flow-guiding cavity is formed, with an inner diameter of 1.2mm to 2mm. The cavity is completely connected vertically, directly connecting the upper wear-resistant and breathable outer layer mesh and the lower one-way moisture-permeable functional membrane layer micropores to achieve vertical water vapor flow and discharge.

[0009] Specifically, the unidirectional moisture-permeable membrane layer adopts a bidirectional hydrophobic gradient modified polytetrafluoroethylene microporous membrane with an overall thickness of 8μm to 12μm. The membrane has a through-type micropore size gradient distribution inside, with micropores of 0.3μm to 0.4μm near the partitioned flow-guiding buffer layer and micropores of 0.1μm to 0.2μm near the gradient moisture-absorbing and moisture-guiding liner layer, forming a unidirectional guiding structure with gradually expanding pore size from the inside to the outside. Water vapor can pass smoothly from the small pore size side to the large pore size side, while liquid water cannot permeate in the reverse direction due to surface tension.

[0010] Specifically, the foot-fitting elastic padding layer is only independently set in the forefoot pressure area and the heel wrapping area, and no padding layer is set in the arch and the middle of the instep, retaining a large area of ​​continuous breathable channels to avoid the foot-fitting elastic padding layer completely covering and blocking the air flow. The foot-fitting elastic padding layer is integrally stamped and formed by open-pore EVA elastic foam mold. The inside of the foam mold has three-dimensional interconnected breathable micropores with a pore diameter of 0.3mm to 0.7mm. Through-type circular large breathable holes with a diameter of 1mm to 1.5mm are opened on the upper and lower surfaces of the foot-fitting elastic padding layer corresponding to the honeycomb cavity of the buffer layer. The airflow between the upper and lower layers can directly pass through the padding layer for exchange, and there will be no moisture retention layer due to the sealing of the padding layer.

[0011] Specifically, the foot-fitting elastic padding layer features a differentiated thickness design with the forefoot padding layer being 2mm to 3mm thick and the heel padding layer being 3.5mm to 4.5mm thick, matching the different cushioning needs of the forefoot and heel. The edge of the foot-fitting elastic padding layer is set with a gradually thinning transition zone, where the thickness gradually decreases from the main body of the padding layer to 0.5mm, smoothly connecting with the surrounding non-padding areas without obvious step gaps, preventing air bubbles and delamination of the interlayer when bending.

[0012] Specifically, the upper and lower surfaces of the foot-shaped elastic padding layer are both covered with an ultra-thin breathable non-woven fabric isolation layer. The non-woven fabric has a basis weight of 15g / ㎡ and is covered with 0.2mm micro-breathing holes. The isolation layer only prevents foam debris from falling off and does not block water vapor from penetrating.

[0013] Specifically, the foot-fitting elastic padding layer contains 2% to 4% porous mineral powder moisture-absorbing particles mixed with the raw materials. These particles are evenly dispersed inside the foam substrate and can temporarily absorb excess sweat and moisture. As the temperature inside the shoe decreases, the moisture is automatically released to the outside, maintaining stable local humidity.

[0014] The beneficial effects of this invention are: Through a five-layer gradient structure consisting of a wear-resistant and breathable outer layer, a zoned air-guiding and buffering layer, a one-way breathable membrane layer, a gradient moisture-wicking lining layer, and a foot-fitting elastic padding layer, as well as four differentiated material designs for different foot zones—a high-heat breathable zone in the forefoot, a torsional support zone in the arch, a heel wrapping buffer zone, and a main breathable zone in the midfoot—this design solves multiple defects of traditional shoe uppers, such as the inability to balance breathability and support, sweat backflow, rainwater intrusion, interlayer adhesive blocking of vents, and localized stuffy dead corners. The multi-layered, dotted composite structure enhances overall breathability, honeycomb-shaped air-guiding cavities create microcirculation within the shoe, and a one-way hydrophobic membrane allows for unidirectional moisture removal. The zoned, differentiated weaving matches the sweating and stress characteristics of different parts of the foot, maintaining a dry shoe cavity even during high-intensity exercise and prolonged wear, inhibiting fungal growth, and improving wearing comfort. Furthermore, when the multi-layered structure is bent, the layers rely on dotted adhesive to create a slight relative sliding, releasing bending stress and preventing peeling and delamination after long-term wear, thus extending the lifespan of the shoe upper. Attached Figure Description

[0015] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is a schematic diagram of a breathable and moisture-wicking shoe upper structure according to the present invention; In the diagram: 100, wear-resistant and breathable outer layer; 200, zoned flow-guiding buffer layer; 300, one-way moisture-permeable membrane layer; 400, gradient moisture-absorbing and moisture-wicking inner lining layer; 500, foot-shaped elastic padding layer. Detailed Implementation

[0016] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0017] Please see Figure 1This invention provides a technical solution: a breathable and moisture-wicking shoe upper structure, which adopts a five-layer gradient composite structure from the outside to the inside, namely, a wear-resistant and breathable outer layer 100, a zoned flow-guiding and buffering layer 200, a one-way moisture-wicking functional membrane layer 300, a gradient moisture-absorbing and moisture-wicking inner lining layer 400, and a foot-shaped elastic padding layer 500. The five-layer structure is formed by zoned dotted breathable adhesive composite molding, with the diameter of the adhesive dots controlled at 0.8mm to 1.5mm and the center distance between adjacent adhesive dots at 3mm to 6mm. Only local point bonding is used, retaining more than 90% of the continuous breathable channels, completely avoiding the defect of the entire adhesive layer blocking micropores.

[0018] The upper is divided into four functional zones based on the pressure and sweat distribution of the human foot: a high-heat breathable zone in the forefoot, a torsional support zone in the arch, a heel wrapping buffer zone, and a main breathable zone in the midfoot. The porosity, membrane pore size, yarn density, and elastic modulus of the five layers in the four zones are configured with different gradients. Among them, the wear-resistant and breathable outer layer 100 in the main breathable zone in the midfoot and the high-heat breathable zone in the forefoot uses a large-pore three-dimensional fly-knitted mesh with an equivalent diameter of 1.2mm to 2mm and a porosity of 65% to 75%. The one-way breathable membrane layer 300 uses a modified polytetrafluoroethylene hydrophobic microporous membrane with a pore size of 0.2μm to 0.4μm, which only allows water vapor to pass through from the inside of the shoe to the outside, and prevents external liquid rainwater from seeping in.

[0019] The abrasion-resistant and breathable outer layer 100 of the arch torsional support area adopts a high-low density alternating jacquard weave structure. The high-density woven strips are continuously arranged in the transverse direction of the arch, with a width of 8mm to 12mm. The strips are embedded with ultra-fine high-elastic polyester multifilaments to improve transverse tear resistance. Continuous long breathable channels with a width of 4mm to 6mm are reserved between the high-density woven strips to balance support rigidity and basic breathability.

[0020] The heel buffer zone is reinforced with a thickened partitioned buffer layer 200. The buffer layer is woven in three dimensions to form a honeycomb-shaped airflow cavity that runs through the shoe. The cavity height is 0.5mm to 1mm, which forms a convection channel for the circulation of hot and humid air inside the shoe, accelerating the outward dissipation of moisture from the sealed area of ​​the heel.

[0021] The gradient moisture-wicking inner lining 400 is made of double-layer heterogeneous polyester yarn plain weave. The side close to the skin is made of highly absorbent irregular cross-section yarn, while the outer side is made of low absorbent and hydrophobic filaments, forming a moisture-wicking gradient from the inside out, preventing sweat from seeping back into the skin after saturation.

[0022] The 500 foot-fitting elastic padding layer is only placed at the contact points of the forefoot and heel. It uses open-pore high-elastic foam with breathable micropores inside the foam to ensure gas exchange between the upper and lower layers.

[0023] The partitioned flow-guiding buffer layer 200 is made of three-dimensional hollow elastic knitted fabric. The fabric has continuous air-guiding grooves in both the longitudinal and transverse directions. The grooves are precisely aligned with the micropores of the one-way breathable membrane layer 300 and the mesh of the wear-resistant and breathable outer layer 100 to form a through-type three-dimensional breathable channel. Sweat generated by the feet in the shoe cavity is first quickly absorbed by the gradient moisture-absorbing and moisture-guiding lining layer 400, and then dispersed laterally to the entire shoe surface through the three-dimensional grooves of the partitioned flow-guiding buffer layer 200. Subsequently, water vapor is discharged unidirectionally to the wear-resistant and breathable outer layer 100 by the hydrophobic micropores of the one-way breathable membrane layer 300, and finally diffused to the outside air through the large-diameter mesh of the outer layer. At the same time, rainwater and water mist cannot penetrate the one-way breathable membrane layer 300 and enter the shoe cavity in the opposite direction.

[0024] By employing a five-layer gradient structure and four differentiated material designs for different foot zones, this shoe addresses multiple shortcomings of traditional uppers, such as the inability to balance breathability and support, sweat backflow, rainwater intrusion, blocked ventilation holes by interlayer adhesives, and localized hot and stuffy areas. The multi-layered, dot-matrix composite structure enhances overall breathability, while honeycomb-like air-guiding cavities create microcirculation within the shoe. A unidirectional hydrophobic membrane allows for one-way moisture removal, and the differentiated weaving in different zones matches the sweating and stress characteristics of different parts of the foot. This ensures that the shoe cavity remains dry during high-intensity exercise and prolonged wear, inhibiting fungal growth and improving comfort. Furthermore, when the multi-layered structure is bent, the layers rely on dot-matrix adhesives to create a slight relative sliding effect, releasing internal bending stress and preventing the layers from lifting or peeling off after long-term wear, thus extending the lifespan of the upper.

[0025] The wear-resistant and breathable outer layer 100 is made of modified polyester multifilament in a one-piece jacquard fly weave. Before weaving, the polyester multifilament is treated with a hydrophobic and wear-resistant double modification process, which includes two steps: The first step is to immerse the polyester multifilament in a fluorinated hydrophobic emulsion with a mass fraction of 8% to 12% for 25 to 35 minutes at room temperature. After immersion, it is taken out and pre-dried at 110°C for 10 minutes to make the fluorinated hydrophobic component evenly coat the yarn surface, giving the yarn hydrophobic and stain-resistant properties and preventing outdoor dust and water stains from adsorbing and clogging the mesh. The second step involves plasma surface bombardment treatment with a bombardment power of 1200W to 1600W and a treatment time of 40s to 60s. This process creates a microscopic rough structure on the yarn surface, which enhances the adhesion to the zoned dotted breathable adhesive and increases the surface abrasion resistance coefficient, thereby improving the surface's resistance to pilling and scratching.

[0026] The flyknit weaving process employs differentiated weaving densities for the four main zones. The main breathable zone in the middle of the instep and the high-heat breathable zone in the forefoot use a three-up, three-down large-hole plain weave, with 12 to 18 mesh holes per square centimeter to ensure maximum breathability.

[0027] The arch torsion support area uses a jacquard weave with alternating plain and twill weaves. High-density twill strips are continuously formed, and 20% to 30% of aramid microfiber is incorporated into the strips. The transverse tensile breaking strength is increased by more than 90%, meeting the deformation resistance requirements of frequent arch torsion. Continuous plain weave large-pore ventilation channels are retained between the twill strips to avoid the reinforcement area from being completely sealed.

[0028] The heel buffer uses a double-layer superimposed fly-knit structure. The outer layer is a regular hydrophobic mesh fabric, and the bottom layer is an elastic lining made of fine denier yarn. A 0.3mm to 0.6mm breathable gap is reserved between the two layers. The gap is connected to the 200 honeycomb cavity of the lower partitioned flow-guiding buffer layer to accelerate the expulsion of moisture from the sealed space of the heel.

[0029] After the wear-resistant and breathable outer layer (100mm) is woven, it undergoes overall shaping treatment at a temperature of 130℃~140℃, a pressure of 0.2MPa~0.3MPa, and a time of 20 minutes. During the shaping process, the weaving internal stress is released through simultaneous stretching to prevent shrinkage and deformation of the finished product over long-term use. After shaping, a 3μm~6μm thick matte wear-resistant and hydrophobic coating is roller-coated onto the outer surface of the outer layer. The coating uses a water-based polyurethane wear-resistant base mixed with nano-silica wear-resistant powder and fluorinated hydrophobic additives. After roller coating, it is dried and cured at a constant temperature of 70℃ for 15 minutes. The coating only adheres to the surface of the yarn and does not block the internal ventilation channels of the mesh, thus ensuring both surface weather resistance and durability. With multiple benefits including UV protection, abrasion resistance, and hydrophobic self-cleaning, the mesh is less prone to clogging under long-term outdoor sunlight and friction conditions, and the hydrophobic performance decreases by less than 8%. Traditional shoe uppers have only a single woven structure, without differentiated weave, hydrophobic and abrasion-resistant yarn modification, or an ultra-thin protective coating. After sports friction, they quickly fray and clog the pores, and rainwater directly soaks into the yarn and penetrates inward. Through a triple design of yarn modification, zoned jacquard weaving, and an ultra-thin breathable protective coating, the surface abrasion resistance, hydrophobicity, anti-aging, and stain resistance are improved simultaneously without reducing breathability. This solves the technical problems of traditional outer layers, such as easy pore clogging, easy water absorption, breathability failure in stress areas, and aging and embrittlement after long-term use.

[0030] The partitioned air-guiding buffer layer 200 is an integrated three-dimensional hollow knitted fabric, made of double-warp and double-weft elastic spandex multifilaments and conventional polyester hollow yarns. The knitted fabric has integrated longitudinal and transverse air-guiding grooves. The longitudinal grooves run continuously along the upper, with a semi-circular cross-section, a depth of 0.4mm to 0.8mm, and a width of 1mm to 1.8mm. The transverse grooves are arranged continuously along the upper, perpendicularly intersecting and connecting with the longitudinal grooves to form a fully covered three-dimensional mesh air-guiding channel. At the intersection of the grooves, a honeycomb-shaped hollow air-guiding cavity is integrated, with an inner diameter of 1.2mm to 2mm. The cavity is completely open from top to bottom, directly connecting to the upper wear-resistant and breathable outer layer 100 mesh and the lower one-way moisture-permeable functional membrane layer 300 micropores, realizing the vertical flow and exhaust of water vapor.

[0031] Differentiated adjustments were made to the groove density for the four zones. The groove density in the main breathable zone in the middle of the instep and the high-heat breathable zone in the forefoot was increased by 40%, resulting in a larger volume of drainage channels per unit area, which quickly channeled away water vapor generated by the evaporation of large amounts of sweat. The groove depth in the arch torsion support zone was reduced by 0.2mm. At the same time, high-density elastic woven ribs were added between the grooves to improve the lateral support rigidity of the cushioning layer and prevent the cushioning layer from collapsing excessively and blocking the drainage channels when the arch torso twists.

[0032] The honeycomb cavity volume of the heel wrapping cushioning layer is doubled, forming a large-capacity gas cushioning chamber. This solves the problems of gas retention, moisture accumulation, and stuffiness caused by double-layer wrapping of the heel. The zoned flow-guiding cushioning layer is woven with 15% to 25% antibacterial silver ion modified hollow yarn. The silver ion antibacterial component is evenly distributed inside the yarn and will not be quickly lost with washing or friction. The cushioning layer continuously releases antibacterial ions to kill bacteria and mold growing in the channels and eliminate odors inside the shoe upper. Both the upper and lower surfaces of the cushioning layer are embossed with concave and convex micro-textures. The raised points of the micro-textures correspond one-to-one with the dotted breathable adhesive. The adhesive dots only adhere to the raised micro-textures. The groove and honeycomb cavity areas are completely free of adhesive, preserving 100% of the three-dimensional flow-guiding channels and solving the defect of traditional full-surface composite adhesive blocking the breathable passage of the middle flow-guiding layer.

[0033] The proportion of spandex multifilament in the cushioning layer is controlled at 10% to 18%, ensuring that the cushioning layer has an elastic elongation of 200% to 300%. It expands and contracts synchronously with the bending of the foot, and the three-dimensional grooves will not be squeezed and closed when bending, thus maintaining continuous air circulation. Traditional shoe uppers lack independent three-dimensional air-guiding cushioning layers. Multiple layers are directly bonded and squeezed without air circulation space. Sweat and moisture can only penetrate and be discharged locally, which easily leads to local high humidity accumulation. Relying on the crisscross grooves and honeycomb interconnected cavities to build a three-dimensional circulating moisture-guiding channel, moisture is dispersed laterally and discharged vertically. Combined with the zoned differential groove density to match the sweat distribution of the foot, and the built-in long-lasting antibacterial yarn inhibits the growth of microorganisms in the channel, it has the triple functions of cushioning and shock absorption, three-dimensional air guidance, and long-lasting antibacterial effect. It solves the problems of traditional shoe uppers with no air guidance in the middle layer, easy clogging of moisture, easy growth of bacteria, and closure of breathable channels after bending.

[0034] The one-way moisture-permeable membrane layer 300 is made of bidirectional hydrophobic gradient modified polytetrafluoroethylene microporous membrane with an overall thickness of 8μm to 12μm. The membrane has a through-type micropore size gradient distribution inside, with micropores of 0.3μm to 0.4μm near the partitioned flow-guiding buffer layer 200 and micropores of 0.1μm to 0.2μm near the gradient moisture-absorbing and moisture-guiding inner liner layer 400. This forms a one-way guiding structure with the pore size gradually increasing from the inside to the outside. Water vapor can pass smoothly from the small pore size side to the large pore size side, while liquid water cannot permeate in the reverse direction due to surface tension.

[0035] During the film production stage, 3%–5% by mass of nano-fluorinated silicon hydrophobic powder is uniformly mixed into the raw materials. The powder is evenly dispersed on the inner wall of the film's micropores, maintaining the hydrophobic properties of the micropores throughout the process. This prevents hydrophilic sweat and salt from adhering to the micropores and causing blockage after long-term use. The top and bottom surfaces of the film undergo dot-shaped corona activation treatment with a power of 900W–1100W and a processing speed of 18m / min. Activation is only performed at the corresponding adhesive dots to form bonding points. The groove and cavity areas are not corona treated to preserve the complete hydrophobic microporous structure. The film thickness is finely adjusted according to the four major zones of the shoe upper. The film thickness in the high-heat areas of the instep and forefoot is set to the lower limit of 8μm to maximize moisture permeability. The film thickness in the stress areas of the arch and heel is set to the upper limit of 12μm to improve the film's tensile and tear resistance, making it less prone to breakage and leakage under torsion and bending conditions. Before film lamination, micro-auxiliary ventilation holes with a diameter of 0.5mm are opened in the corresponding honeycomb cavities and channeling groove areas, which are connected to the cushioning layer. Precise cavity alignment further enhances the speed of moisture removal in high-perspiration areas. A 5mm-8mm sealing area is reserved between the edge of the membrane and the cut line of the shoe upper. The sealing area uses a narrow strip heat-pressed seal to prevent rainwater from seeping in through the gaps between layers. Micro-ventilation gaps are retained inside the sealing area to ensure that gas exchange at the edge is not blocked. Traditional ordinary breathable membranes have a single pore size without gradient, which cannot achieve unidirectional hydrophobic moisture wicking. Sweat salts and skin oils can easily adhere to the micropores and cause permanent blockage. The membranes do not have zoned thickness adaptation, and they are prone to cracking and water seepage in areas subjected to stress and bending. The gradient pore size modified membrane achieves unidirectional water vapor passage by relying on the difference between the inner and outer pore sizes. The internal nano-hydrophobic powder keeps the micropores from clogging in the long term. The zoned thickness adaptation balances moisture permeability and structural strength. Combined with the aligned auxiliary vents, it greatly improves the speed of moisture removal in high-heat areas. At the same time, the edge sealing structure prevents water seepage between layers. It balances the two contradictory performances of breathability and moisture permeability and outdoor waterproofing, and solves the defects of traditional breathable membranes, such as easy clogging, easy damage, inability to balance waterproofing and breathability, and lack of zoned adaptation.

[0036] The gradient moisture-wicking lining layer 400 is made of double-layered plain weave yarn with different cross-sections. The inner layer yarn, which is in direct contact with the skin of the foot, is made of trilobal high absorbency modified polyester yarn. Each yarn has three water-guiding grooves on its cross-section, with an instantaneous water absorption rate of ≥1.2g / s, which can quickly absorb a large amount of sweat from the feet. The outer layer yarn, which is away from the skin, is made of circular hydrophobic low absorbency polyester filaments. The surface of the outer yarn is covered with a fluorine hydrophobic film, with a water absorption rate of less than 0.1g / s. This forms a directional moisture-guiding gradient of "high absorbency inner layer and low hydrophobic outer layer" in the thickness direction of the lining layer. After the sweat is quickly absorbed by the inner layer, it can only be conducted to the outer layer in one direction and cannot seep back to the skin, thus solving the problem of sticky and stuffy feet after ordinary linings are full of sweat.

[0037] The lining layer features differentiated yarn ratios for four zones. In the high-heat, sweat-prone areas of the forefoot and instep, 80% of the yarn is lobed absorbent yarn and 20% is hydrophobic filament, maximizing instantaneous moisture absorption capacity. In the arch and heel areas, 50% of the yarn is lobed absorbent yarn and 50% is hydrophobic filament, increasing the lining's elasticity and tensile strength to accommodate frequent twisting and compression. During the weaving process, a longitudinal hydrophobic guide rib is woven every 1cm to 1.5cm. The guide ribs are made entirely of pure hydrophobic filament and run longitudinally throughout the entire lining. The absorbed sweat is quickly dispersed laterally along the guide ribs to the entire lining, preventing localized saturation of sweat.

[0038] After the inner lining is woven, it undergoes a hydrophilic gradient setting treatment. The setting solution consists of a highly hydrophilic impregnation solution for the inner layer and a low hydrophobic spraying solution for the outer layer. The setting temperature is 120℃, which permanently sets the hydrophilic and hydrophobic gradient between the inner and outer layers, ensuring that the moisture wicking gradient does not diminish after multiple washes. A dotted, long-lasting antibacterial coating is evenly printed on the skin-contact area of ​​the inner lining. The coating uses a mixture of plant-derived antibacterial extracts of Artemisia argyi and cloves, combined with a water-based polyurethane carrier. Each coating dot has a diameter of 0.6mm, maintaining a continuous breathable area between the dots without blocking fabric pores. The coating slowly releases antibacterial components, inhibiting fungi on the skin surface. This double-layer gradient lining reduces foot odor and promotes bacterial growth. Traditional linings use a single hydrophilic fabric without a directional moisture-wicking gradient. After saturation, sweat seeps back into the skin. There is no zoned moisture-wicking adaptation, resulting in insufficient moisture absorption capacity in high-heat areas and poor elasticity in stress areas, making them prone to pilling. This double-layer gradient lining relies on the difference between the hydrophilic and hydrophobic properties of the inner and outer layers to achieve unidirectional sweat wicking. The zoned yarn ratio matches the amount of sweat produced, and the longitudinal hydrophobic ribs disperse localized sweat. Combined with a dotted breathable and antibacterial coating, it simultaneously achieves multiple effects such as rapid moisture absorption, directional moisture wicking, long-lasting antibacterial effect, and dryness without backflow. This solves the technical defects of conventional linings, such as stickiness, localized dampness, and easy growth of odor-causing bacteria.

[0039] The 500-type foot-fitting elastic padding layer is independently placed only in the forefoot pressure zone and heel wrapping zone, with no padding layer in the arch and midfoot area, fully preserving a large area of ​​continuous ventilation channels and avoiding the blockage of airflow by the padding layer covering the entire area. The elastic padding layer is made of open-cell EVA elastic foam molded in one piece by stamping. The foam mold has three-dimensional interconnected ventilation micropores with a pore diameter of 0.3mm to 0.7mm. Through-type circular ventilation holes with a diameter of 1mm to 1.5mm are opened on the upper and lower surfaces of the padding layer corresponding to the honeycomb cavity of the cushioning layer. The airflow between the upper and lower layers can directly pass through the padding layer for exchange, without the formation of a moisture retention layer due to the padding layer being sealed. The padding layer thickness is designed with different zones: the forefoot padding layer is 2mm to 3mm thick, and the heel padding layer is 3.5mm to 4.5mm thick, matching the different cushioning needs of the forefoot and heel. The edge of the padding layer has a gradually thinning transition zone, with the thickness gradually decreasing from the main body of the padding layer to 0.5mm, smoothly connecting with the surrounding non-padding areas without obvious step gaps, preventing air bubbles and delamination of the interlayer when bending.

[0040] Both the upper and lower surfaces of the padding layer are bonded with an ultra-thin breathable non-woven fabric isolation layer. The non-woven fabric weighs 15g / ㎡ and is covered with 0.2mm micro-ventilation pores. The isolation layer only prevents foam debris from falling off and does not block moisture penetration. The padding layer contains 2% to 4% porous mineral powder moisture-absorbing particles mixed with the raw materials. The particles are evenly dispersed inside the foam substrate and can temporarily absorb excess sweat and moisture. As the shoe cavity temperature decreases, the moisture is automatically released to the outside, maintaining stable local humidity. The padding layer is bonded to the lower surface of the gradient moisture-absorbing and wicking lining layer 400mm only through dotted breathable adhesive. The bonding points avoid all through-holes, and the pore areas are completely uncovered with adhesive, ensuring consistent moisture absorption throughout the process. The vertical ventilation channels are unobstructed; traditional shoe upper cushioning pads are mostly full-coverage dense foam without through-breathable micropores, blocking the upper and lower ventilation channels. The impact cushioning area forms a closed and stuffy space, and the padding layer does not have moisture-absorbing and slow-release particles, resulting in long-term dampness after local sweating. This padding layer is only arranged in local points, with full-open ventilation, and the thickness of each zone is adapted to the cushioning needs. It has built-in porous mineral powder to temporarily store moisture without occupying the main ventilation area of ​​the shoe upper. While improving the cushioning softness of the forefoot and heel, it does not destroy the overall three-dimensional ventilation and moisture-wicking channels, solving the technical problems of traditional full-coverage cushioning pads blocking ventilation, causing local stuffiness, and lacking humidity regulation capabilities.

[0041] The five-layer composite structure adopts a step-by-step, zoned, point-based hot-pressing composite process. The complete process steps are as follows: The first step involves separately preparing five substrates: a wear-resistant and breathable outer layer 100, a zoned flow-guiding buffer layer 200, a one-way moisture-permeable functional membrane layer 300, a gradient moisture-absorbing and moisture-guiding inner lining layer 400, and a foot-shaped fit elastic pad layer 500. Each substrate is pre-cut into blocks according to four zones, with precise alignment marking lines reserved at the edges of the zones. The second step is to prepare the zoned dotted breathable adhesive. The adhesive is a low-viscosity, high-breathable water-based polyurethane adhesive. Hollow breathable microspheres with a diameter of 0.5mm to 1mm are uniformly mixed in the adhesive. After the microspheres are cured, they form interconnected micro-breathable channels inside the adhesive dots, preventing the adhesive dots from being completely sealed and blocking local airflow. The viscosity of the adhesive is controlled at 1200 to 1600 mPa·s, and the solid content is 30% to 38%. The adhesive is applied using a CNC dot matrix spraying device. The adhesive dots are precisely sprayed on the upper and lower surfaces of the zoned flow-guiding buffer layer 200 according to the preset array. The adhesive is only sprayed at the preset points, and no adhesive is sprayed in the groove and honeycomb cavity areas. The third step is layered alignment and bonding. First, the wear-resistant and breathable outer layer 100 is aligned and bonded with the sprayed and glued partitioned flow-guiding buffer layer 200. After the alignment marks are completely aligned, it is sent into a low-temperature segmented hot press. The hot pressing temperature is 65℃~75℃, the hot pressing pressure is 0.15MPa~0.25MPa, and the single hot pressing time is 12s. Only the glue dots are heated and bonded, and there is no pressure squeezing in the groove cavity, maintaining the integrity of the three-dimensional flow-guiding channel without collapse. The fourth step is to remove the semi-finished product and attach the one-way moisture-permeable membrane layer 300 to the adhesive dots on the lower surface of the partitioned flow-guiding buffer layer 200. Repeat the low-temperature segmented dot hot pressing process so that the micropores of the membrane will not be squeezed and closed by high temperature and high pressure. The fifth step is to align and heat-press the gradient moisture-wicking inner liner 400 with the adhesive dots on the lower surface of the functional membrane. Then, the foot-shaped elastic padding 500 is attached to the corresponding points on the forefoot and heel, with only localized dotted bonding of the padding. The semi-finished product after the sixth step of lamination is sent to a 40℃ constant temperature curing chamber for 24 hours to release the interlayer stress generated by the layered lamination. During the curing process, the air is continuously circulated at a low speed to accelerate the evaporation of moisture inside the adhesive and avoid the long-term moisture absorption caused by residual hydrophilic groups in the adhesive. After curing, the outer contour of the shoe upper is cut along the alignment mark line. The cut edges are sealed with ultrasonic narrow strip heat sealing, with a sealing width of 2mm, which only seals the gaps between layers, leaving a small ventilation gap inside the heat seal. Traditional shoe uppers use a whole-area glue coating and hot-pressing composite, where the glue fills all the pores of the fabric and the micropores of the film, resulting in a significant decrease in air permeability. Without segmented low-temperature hot pressing, the high temperature and high pressure easily cause the middle channeling groove to collapse, and the internal stress between layers cannot be released. Long-term bending leads to delamination and glue separation. This step-by-step, segmented dot spraying, low-temperature segmented hot pressing, and constant temperature curing composite process uses glue dots with hollow breathable microspheres. Non-bonded areas are covered with zero glue, and the three-dimensional channeling structure is not deformed by compression throughout the process. Curing eliminates interlayer stress and eliminates the three major defects of glue clogging micropores, interlayer delamination, and collapse of channeling channels from the production process level, improving the breathability stability and interlayer adhesion durability of the finished product.

[0042] The upper is precisely divided into four functional zones according to the standard adult shoe last dimensions, with seamless, one-piece molding at the boundaries and continuous transitions between zones. Specific dimensional standards are as follows: the upper boundary of the main ventilation zone in the midfoot is 10mm-15mm from the top edge of the shoe opening, and the lower boundary extends to the upper arch dividing line, covering 70% of the entire instep width. This is the area with the highest breathability, and the entire structure uses a full-coverage, large-pore flyknit structure without TPU or dense lamination. The high-heat ventilation zone in the forefoot extends from the tip of the forefoot to the front arch dividing line, with a longitudinal length of 40mm-60mm, covering the entire forefoot toe area. This area has the highest friction, metabolic heat generation, and perspiration during walking, and all five layers of materials utilize this design. It features the highest porosity and maximum moisture permeability. The arch torsional support zone is located between the forefoot ventilation zone and the heel buffer zone, with a longitudinal width of 25mm to 35mm. It completely wraps around the inner and outer sides of the arch. This area is equipped with continuous high-density woven support strips and a thickened drainage and cushioning layer. Its lateral tear resistance is 1.8 times that of the other zones. Long, continuous ventilation channels are reserved between the support strips to balance torsional support and basic breathability. The heel wrap buffer zone extends from the rear arch dividing line to the bottom of the heel, with a vertical height of 30mm to 45mm. It wraps around the sides of the heel. This area is equipped with a thickened honeycomb drainage cavity pad and a double-layer outer mesh fabric to form a closed buffer drainage cavity, solving the problem of moisture accumulation in the sealed heel.

[0043] The transition zone between the four zones is uniformly set at 5mm width. This transition zone employs a gradient weave, gradient film thickness, and gradient cushioning layer groove density design, smoothly transitioning material parameters from one zone to adjacent zones without abrupt performance changes, thus avoiding precipitous drops in breathability and support performance at zone seams. All zone boundaries are distinguished solely by the material parameters of the weave, film, and cushioning layers, with seamless, heat-pressed seams and continuous molding, preventing leaks and delamination at seams. Traditional breathable uppers lack standardized zone dimensions, with breathable and support zones appearing randomly. The traditional upper design addresses the shortcomings of traditional shoes, such as poor ventilation in high-heat, sweat-prone areas, and gaps between sections where breathable mesh covers a large area that creates stuffy, hot corners. The standardized section dimensions are matched to the anatomical sweating and stress distribution patterns of the human foot. A gradient transition design eliminates abrupt performance changes. The seamless, one-piece construction achieves a synergistic effect of "maximizing breathability in high-heat areas, strengthening support in torsional zones, cushioning and wicking moisture in the heel area, and providing ventilation throughout the instep." This structural layout solves the problems of unreasonable ventilation and support area layout, localized stuffiness, and water leakage in traditional shoe uppers.

[0044] Before leaving the factory, the finished shoe uppers undergo five specific performance tests. Only after all tests are passed can the shoes be put into storage. The five test indicators set exclusive judgment standards for five core functions: breathability, moisture permeability, waterproofing, interlayer bonding, and antibacterial properties. The first test, breathability, was conducted using a fabric breathability tester according to national standards. The breathability of the main breathable area on the instep was ≥6500mm / s, the breathability of the high-heat breathable area in the forefoot was ≥6000mm / s, the breathability of the arch support area was ≥2800mm / s, the breathability of the heel buffer zone was ≥3200mm / s, and there were no closed dead corners with a breathability of less than 2500mm / s in any area of ​​the entire upper. The second test, unidirectional moisture permeability and waterproofing, was conducted using a moisture permeability tester. Under normal temperature (25℃) and humidity (60%) conditions, the overall moisture permeability of the shoe upper was ≥8500g / (㎡・24h). Simultaneously, a continuous 30-minute spray waterproofing test was performed with a water pressure of 0.08MPa. No liquid water seeped into the shoe cavity. After spraying, the moisture permeability was retested after 24 hours of standing. The performance degradation rate was less than 6%. The third test is the interlayer adhesion durability test. A sample of the shoe upper bending area is subjected to 10,000 reciprocating bending tests. The bending angle is 0° to 90° and the bending frequency is 60 times / min. After bending, visual inspection shows no delamination, lifting, or bubbles. The adhesive peel strength is ≥1.2N / mm and there is no adhesive drop. The fourth test, long-lasting antibacterial performance, was conducted in accordance with the national standard for antibacterial plastics. The antibacterial rate against Escherichia coli, Staphylococcus aureus, and Candida albicans was ≥92% after 24 hours, and the antibacterial rate was still ≥85% after 50 washes of the finished product. The fifth test, abrasion resistance and pore-clogging resistance, uses a Martindale abrasion tester for 4000 cycles. After the test, there was no large-area clogging of the mesh in the shoe upper, and the decrease in breathability was less than 10%. Traditional shoe uppers lack differentiated performance testing for different areas and only judge the overall breathability index. They cannot identify localized dead zones such as the arch and heel. They also lack supporting testing items for spray waterproofing, bending durability, long-lasting antibacterial effect after washing, and abrasion resistance and pore-clogging resistance. A large number of finished products have hidden defects such as localized breathability failure, loss of antibacterial effect after washing, delamination after bending, and water seepage after rain entering the market. Regional breathability testing accurately identifies stuffy dead zones and is equipped with comprehensive testing standards for waterproofing, durability, long-lasting antibacterial effect, and abrasion resistance. It strictly limits the threshold for the decline of various performances to ensure that the breathability, moisture permeability, waterproofing, antibacterial effect, and interlayer bonding performance of finished products remain stable during long-term use, thereby reducing the defect rate of finished products.

[0045] The mass production process employs a modular prefabrication and overall alignment assembly method to improve the versatility of different shoe sizes and styles, reduce mold opening costs, and the complete processing steps include: The modular prefabrication process involves prefabricating four independent prefabricated modules: the instep main ventilation module, the forefoot high-heat ventilation module, the arch torsion support module, and the heel wrapping and cushioning module. Each module is pre-composite with five layers of layered dot-matrix, differentiated configuration of zoned materials, and ultrasonic pre-sealing of the edges. A single module can adapt to 3 to 4 adjacent shoe sizes. It can adapt to different shoe lasts by simply adjusting the module's cutting outline size, without having to re-weave and composite the entire set. The last alignment and positioning process involves selecting and matching four prefabricated modules according to the target shoe size. The alignment marks on the edge of the modules are matched with the positioning grooves on the standard last surface. The modules are connected by a 5mm gradient transition strip, and a micro-ventilation gap is retained inside the overlap. The entire surface is not sealed by heat pressing. In the overall splicing and shaping process, after the four major modules are joined together, they are sent into the overall heat-setting mold of the shoe upper. The shaping temperature is 115℃, and the low temperature and low pressure shaping takes 18 minutes. Only the overlapping transition zone is slightly heat-pressed and bonded, and the five-layer breathable structure of each module is not compressed. The edge sealing and cutting process involves ultrasonic heat sealing and cutting along the outer contour of the shoe upper after shaping, sealing all module overlap gaps, and leaving continuous micro-ventilation channels inside the edge sealing. The assembly process involves 500 steps to fit the foot shape with elastic padding. Perforated elastic padding is only applied to the corresponding points on the inner side of the forefoot and heel modules. The other modules are not fitted with padding, thus preserving the full-area ventilation channels.

[0046] Traditional breathable shoe uppers use a one-piece woven composite process. Each shoe size and style requires a separate woven mold and a separate layered composite production line. Small-batch, multi-style production results in high mold opening costs and cumbersome changeover processes. Without a modular prefabricated structure, if a single fabric or section has a defect, the entire shoe upper is scrapped, resulting in significant material waste. This product features four independently prefabricated functional modules that are compatible with multiple shoe sizes. Modules can be replaced and inspected individually. Defective modules do not require the entire shoe upper to be scrapped, increasing material utilization by over 25%. Changeovers only require adjusting the module's cutting size, without replacing the entire woven and composite equipment. This simplifies the production process and increases changeover efficiency by 60%. Furthermore, modular prefabrication allows for separate breathability, moisture permeability, and antibacterial quality inspections of each module, eliminating defects in individual modules in advance and reducing the finished product defect rate. It combines the advantages of large-scale mass production, flexible production of multiple styles, high material utilization, and high finished product yield, solving the mass production defects of traditional one-piece shoe uppers, such as high mold opening costs, slow changeovers, scrapping of entire defective parts, and difficulty in inspecting quality by section.

[0047] Although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A breathable and moisture-wicking shoe upper structure, characterized in that, The structure comprises, from the outside in, a wear-resistant and breathable outer layer (100), a zoned flow-guiding buffer layer (200), a one-way breathable membrane layer (300), a gradient moisture-wicking inner lining layer (400), and a foot-fitting elastic pad layer (500). These layers are formed using a zoned, dotted breathable adhesive composite molding process. The diameter of the adhesive dots is controlled between 0.8mm and 1.5mm, and the center-to-center distance between adjacent dots is 3mm to 6mm, achieving localized point bonding and retaining at least 9... The continuous breathable channel with 0% avoids the defect of the whole adhesive layer blocking the micropores. The structure formed by the wear-resistant and breathable outer layer (100), the zoned flow-guiding buffer layer (200), the one-way moisture-permeable functional membrane layer (300), the gradient moisture-absorbing and moisture-wicking inner lining layer (400) and the foot-shaped fit elastic pad layer (500) is divided into the forefoot high heat breathable zone, the arch torsion support zone, the heel wrapping buffer zone and the middle of the instep main breathable zone according to the human foot's pressure and sweat distribution. The porosity, film pore size, yarn density and elastic modulus of the forefoot high heat breathable zone, the arch torsion support zone, the heel wrapping buffer zone and the middle of the instep main breathable zone are configured with different gradients.

2. The breathable and moisture-wicking shoe upper structure according to claim 1, characterized in that: The wear-resistant and breathable outer layer (100) of the main breathable area in the middle of the instep and the high-heat breathable area in the forefoot is made of a three-dimensional fly-knitted mesh with a large pore size. The equivalent diameter of the mesh is 1.2mm to 2mm and the porosity is 65% to 75%. The one-way breathable membrane layer (300) is made of modified polytetrafluoroethylene hydrophobic microporous membrane with a pore size of 0.2μm to 0.4μm, which only allows water vapor to penetrate from the inside of the shoe to the outside in one direction, and blocks external liquid rainwater from seeping in the opposite direction. The wear-resistant and breathable outer layer (100) of the arch torsion support area adopts a high-low density alternating jacquard weave structure. The high-density woven strips are continuously arranged in the transverse direction of the arch, with a width of 8mm to 12mm. The high-density woven strips are embedded with ultra-fine high-elastic polyester multifilaments to improve the transverse tear resistance. Continuous long breathable channels with a width of 4mm to 6mm are reserved between the high-density woven strips to balance support rigidity and basic breathability. The heel wrapping buffer zone is equipped with a thickened partitioned flow-guiding buffer layer (200). The partitioned flow-guiding buffer layer (200) is three-dimensionally woven to form a honeycomb-shaped flow-guiding cavity that runs through the upper and lower parts. The cavity height is 0.5mm to 1mm, forming a convection channel for the circulation of hot and humid gas inside the shoe, which accelerates the outward dissipation of moisture from the sealed area of ​​the heel. The gradient moisture-wicking inner lining (400) is made of double-layer heterogeneous polyester yarn plain weave. The side close to the skin is made of highly absorbent irregular cross section yarn, and the outer side is made of low absorbent hydrophobic filament, forming a moisture-wicking gradient from the inside to the outside, preventing sweat from back seeping back onto the skin after saturation. The foot-fitting elastic padding layer (500) is only placed at the contact points of the forefoot and heel, and is made of open-pore high-elastic foam with through-hole breathable micropores inside the foam, which does not block the gas exchange between the upper and lower layers; the partitioned flow-guiding buffer layer (200) is made of three-dimensional hollow elastic knitted fabric, and the fabric has continuous air-guiding grooves in both the longitudinal and transverse directions. The grooves are precisely aligned with the micropores of the one-way breathable functional membrane layer (300) and the mesh of the wear-resistant and breathable outer layer (100) to form a through-hole three-dimensional breathable passage. Sweat generated by the feet inside the shoe cavity is first quickly absorbed by the gradient moisture-wicking lining layer (400), and then dispersed laterally to the entire shoe surface through the three-dimensional grooves of the partitioned flow buffer layer (200). Subsequently, water vapor is discharged unidirectionally to the wear-resistant and breathable outer layer (100) by the hydrophobic micropores of the one-way breathable membrane layer (300), and finally diffused to the outside air through the large-pore mesh of the outer layer. At the same time, rainwater and water mist cannot penetrate the one-way breathable membrane layer (300) and enter the shoe cavity in the opposite direction.

3. The breathable and moisture-wicking shoe upper structure according to claim 2, characterized in that: The wear-resistant and breathable outer layer (100) is made of modified polyester multifilament in one-piece jacquard fly weave. Before weaving, the polyester multifilament is subjected to hydrophobic and wear-resistant double modification treatment. The modification step includes two steps. The first step is to immerse the polyester multifilament in 8% to 12% by mass of fluorine hydrophobic emulsion at room temperature for 25 to 35 minutes. After taking it out, it is pre-dried at 110°C for 10 minutes to make the fluorine hydrophobic component uniformly coat the yarn surface, giving the yarn hydrophobic and stain-resistant properties and preventing outdoor dust and water stains from adsorbing and clogging the mesh. The second step is to use plasma surface bombardment treatment with a bombardment power of 1200W to 1600W and a treatment time of 40s to 60s to form a micro-uneven rough structure on the yarn surface, which improves the adhesion to the partitioned dotted breathable adhesive, while increasing the surface wear friction coefficient and improving the surface anti-pilling and anti-scratch performance. The flyknitting process employs differentiated weaving densities for the forefoot high-heat breathable zone, the arch torsion support zone, the heel wrapping buffer zone, and the main breathable zone in the middle of the instep. The main breathable zone in the middle of the instep and the high-heat breathable zone in the forefoot use a three-up-three-down large-hole plain weave structure, with 12 to 18 mesh holes per square centimeter to ensure maximum breathability. The heel buffer zone adopts a double-layer superimposed fly-knit structure. The surface layer is a conventional hydrophobic mesh fabric, and the bottom layer is an elastic lining fabric woven with fine denier yarn. A 0.3mm to 0.6mm air-breathing gap is reserved between the two layers. The gap is connected to the honeycomb cavity of the lower partitioned flow-guiding buffer layer (200) to accelerate the discharge of moisture from the closed space of the heel.

4. The breathable and moisture-wicking shoe upper structure according to claim 3, characterized in that: After the wear-resistant and breathable outer layer (100) is woven as a whole, it is subjected to overall shaping treatment. The shaping temperature is 130℃~140℃, the shaping pressure is 0.2MPa~0.3MPa, and the shaping time is 20min. During the shaping process, the internal stress of the weaving is released by stretching simultaneously to prevent the finished product from shrinking and deforming after long-term use. After shaping, a matte wear-resistant and hydrophobic coating with a thickness of 3μm~6μm is rolled onto the outer surface of the wear-resistant and breathable outer layer (100). The coating is made of water-based polyurethane wear-resistant base mixed with nano-silica wear-resistant powder and fluorine hydrophobic additive. After rolling, it is dried and cured at a constant temperature of 70℃ for 15min. The coating only adheres to the surface of the yarn and will not block the breathable channels inside the mesh. It takes into account the multiple effects of weather resistance, UV resistance, friction resistance, hydrophobic self-cleaning. Under long-term outdoor light and friction conditions, the mesh is not easily blocked, and the hydrophobic performance decay is less than 8%.

5. The breathable and moisture-wicking shoe upper structure according to claim 4, characterized in that: The partitioned flow-guiding buffer layer (200) is an integral three-dimensional hollow knitted fabric, which is made of double warp and double weft elastic spandex multifilament and conventional polyester hollow yarn. The knitted fabric has an integrally formed longitudinal flow-guiding groove and a transverse flow-guiding groove. The longitudinal groove runs continuously along the upper and lower direction of the shoe upper. The groove cross section is semi-circular, with a groove depth of 0.4mm to 0.8mm and a groove width of 1mm to 1.8mm. The transverse groove is arranged continuously along the upper left and right sides and intersects with the longitudinal groove vertically to form a fully covered three-dimensional mesh flow-guiding channel. The groove intersection is integrally formed with a honeycomb hollow flow-guiding cavity with an inner diameter of 1.2mm to 2mm. The cavity is completely connected from top to bottom and directly connects to the mesh of the upper wear-resistant and breathable outer layer (100) and the micropores of the lower one-way moisture-permeable functional membrane layer (300) to realize the vertical flow and discharge of water vapor.

6. The breathable and moisture-wicking shoe upper structure according to claim 5, characterized in that: The unidirectional moisture-permeable membrane layer (300) is made of bidirectional hydrophobic gradient modified polytetrafluoroethylene microporous film with an overall thickness of 8μm to 12μm. The film has a through-type micropore size gradient distribution inside. The micropore size is 0.3μm to 0.4μm on the side near the partitioned flow-guiding buffer layer (200) and 0.1μm to 0.2μm on the side near the gradient moisture-absorbing and moisture-guiding liner layer (400), forming a unidirectional guiding structure with the pore size gradually increasing from the inside to the outside. Water vapor can pass smoothly from the small pore size side to the large pore size side, while liquid water cannot permeate in the reverse direction due to surface tension.

7. The breathable and moisture-wicking shoe upper structure according to claim 6, characterized in that: The foot-fitting elastic pad (500) is only independently set in the forefoot pressure area and the heel wrapping area. No pad is set in the arch and the middle of the instep, so as to retain a large area of ​​continuous ventilation channels and avoid the foot-fitting elastic pad (500) completely covering and blocking the air flow. The foot-fitting elastic pad (500) is integrally stamped with open-pore EVA elastic foam. The foam has three-dimensional interconnected ventilation micropores with a pore diameter of 0.3mm to 0.7mm. The upper and lower surfaces of the foot-fitting elastic pad (500) have through-type circular ventilation holes with a diameter of 1mm to 1.5mm at the honeycomb cavity position of the buffer layer. The airflow between the upper and lower layers can directly pass through the pad and exchange, and there will be no moisture retention layer due to the sealing of the pad.

8. The breathable and moisture-wicking shoe upper structure according to claim 7, characterized in that: The foot-fitting elastic padding layer (500) features a differentiated thickness design with the forefoot padding layer being 2mm to 3mm thick and the heel padding layer being 3.5mm to 4.5mm thick, matching the different cushioning needs of the forefoot and heel. The foot-fitting elastic padding layer (500) has a gradually thinning transition zone at the edge, with the thickness of the transition zone gradually decreasing from the main body of the padding layer to 0.5mm, smoothly connecting with the surrounding non-padding areas without obvious step gaps, preventing air bubbles and delamination of the interlayer when bending.

9. The breathable and moisture-wicking shoe upper structure according to claim 8, characterized in that: The foot-shaped elastic pad (500) has an ultra-thin breathable non-woven fabric isolation layer pasted on both the upper and lower surfaces. The non-woven fabric has a weight of 15g / ㎡ and is covered with 0.2mm micro-breathing holes. The isolation layer only prevents foam debris from falling off and does not block water vapor from penetrating.

10. The breathable and moisture-wicking shoe upper structure according to claim 9, characterized in that: The foot-fitting elastic padding layer (500) contains 2% to 4% porous mineral powder moisture-absorbing particles mixed with raw materials. The particles are evenly dispersed inside the foam substrate and can temporarily absorb excess sweat and moisture. After the temperature inside the shoe cavity decreases, the moisture is automatically released to the outside, maintaining local humidity stability.

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