A method for manufacturing an arch support sock with a relief cavity, an arch support sock, and a hot press device

Abstract

The application discloses a preparation method of an arch support sock with an avoiding structure, the arch support sock and a hot-pressing device. The avoiding hole, avoiding groove or avoiding cavity is arranged on the bearing part or high-temperature-resistant elastic layer, so that the arch support part at least partially enters or is limited in the avoiding structure in the hot-pressing process, thereby reducing the risk that the convex structure of the arch support part is collapsed, deformed or deviated in positioning. Meanwhile, the covering layer is fixed with the sock surface of the sock body in the foot arch area through the hot-melt connecting layer, so that the arch support part is limited in the area surrounded by the covering layer and the sock body. The hot-melt connecting layer can be in a closed loop shape, an open loop shape, a net shape, a hole shape, a dot matrix shape, a strip shape or a local interval shape structure, so as to consider the connection stability, air permeability and wearing comfort. The application further discloses the arch support sock and the hot-pressing device corresponding to the preparation method.

Description

Technical Field

[0001] This invention relates to the field of wearable technology, specifically to a method for manufacturing arch support socks with an avoidance mold cavity, as well as the arch support socks and a hot pressing device. Background Technology

[0002] Arch support socks, as a type of functional knitted product, provide support to the arch area of ​​the foot by setting a support structure in the sock body. This improves the feeling of pressure on the sole of the foot when wearing them and relieves foot fatigue during prolonged standing or exercise. They are widely used in daily wear, sports protection, and other scenarios.

[0003] Currently, most arch support socks are manufactured by directly attaching the support components to the sock surface and then heat-pressing them in place. However, this method has several technical drawbacks: First, during heat pressing, the support components are prone to displacement or shifting, resulting in insufficient positioning accuracy and affecting the accuracy of the support position. This can even lead to the support components deviating from the arch area and causing discomfort when worn. Second, if the support components lack sufficient clearance during heat pressing, they are easily crushed, misaligned, or deformed, damaging the arc-shaped protrusion structure and affecting support performance. Third, if a continuous, full-surface heat-fused layer is used for pressing in existing solutions, it can easily affect the breathability of the sock and increase the risk of wrinkles in the knitted sock. While using partial connections or perforated, mesh-like heat-fused connection layers can improve breathability, problems such as support component positioning shift, deformation of the protrusion structure under pressure, and insufficient pressing of the connection area may still occur during heat pressing.

[0004] Therefore, it is necessary to provide a method for manufacturing arch support socks, arch support socks, and a hot pressing device that can provide clearance space for arch support components during the hot pressing process, while taking into account positioning stability, reliable connection, and wearing comfort. Summary of the Invention

[0005] To solve at least one of the above-mentioned technical problems, the present invention provides the following technical solution.

[0006] This application discloses a method for preparing an arch support sock, comprising the following steps: preparing a sock body, an arch support component, a cover layer, and a heat-fused bonding layer; positioning the arch support component in the arch area of ​​the sock body, and covering the outside of the arch support component with the cover layer; placing the heat-fused bonding layer in the connection area between the cover layer and the sock body; placing the positioned sock body in a hot-pressing device, the hot-pressing device including a pressing part and a bearing part, the bearing part being provided with a high-temperature resistant elastic layer, the high-temperature resistant elastic layer having a clearance structure corresponding to the position of the arch support component, the clearance structure including clearance holes, clearance grooves, or clearance cavities; during hot pressing, at least a portion of the protruding structure of the arch support component enters or is confined within the clearance structure, the pressing part applies pressure to the connection area corresponding to the heat-fused bonding layer, causing the cover layer to bond to the arch area of ​​the sock body through the heat-fused bonding layer, and forming an arch support sock after cooling.

[0007] Furthermore, the hot-melt bonding layer is at least distributed in the peripheral connection area of ​​the cover layer, and the hot-melt bonding layer has a closed-loop, open-loop, mesh, porous, dot matrix, strip, or locally spaced structure.

[0008] Furthermore, the covering layer and the arch support are bonded together by means of adhesion, partial bonding, dot bonding, strip bonding, hot melt bonding, or non-adhesive covering.

[0009] Furthermore, the avoidance structure is an avoidance hole penetrating the high-temperature resistant elastic layer, or a blind groove, cavity, or irregular cavity formed on the surface of the high-temperature resistant elastic layer; the shape of the avoidance structure is adapted to the outer contour of the arch support.

[0010] Furthermore, in the fourth step of hot pressing, the hot pressing temperature is 170℃ to 210℃, and the hot pressing time is 8s to 20s; after hot pressing is completed, the hot pressing area is subjected to pressure holding and cooling, natural cooling, air cooling, or cold pressing for shaping.

[0011] This application also discloses an arch support sock, including a sock body, an arch support member, a cover layer, and a heat-fused bonding layer; the sock body has an arch area corresponding to the position of the human foot arch; the arch support member is disposed in the arch area of ​​the sock body, and the arch support member is an arc-shaped protrusion, crescent-shaped, sheet-like, or irregularly shaped protrusion structure adapted to the arch area; the cover layer covers the outside of the arch support member; the heat-fused bonding layer is disposed in the connection area between the cover layer and the sock body, and the cover layer is heat-fused to the sock surface of the arch area of ​​the sock body through the heat-fused bonding layer; wherein, the arch support member is located in the area enclosed by the cover layer and the sock body, and the heat-fused bonding layer forms an avoidance area, a non-connection area, a weak connection area, or a breathable area in the corresponding area of ​​the arch support member.

[0012] This application also discloses a hot pressing device for preparing arch support socks, including a pressing part, a bearing part, and a high-temperature resistant elastic layer disposed on the bearing part; the high-temperature resistant elastic layer is provided with a clearance structure corresponding to the position of the arch support member, the clearance structure including clearance holes, clearance grooves or clearance mold cavities, the clearance structure is used to accommodate at least part of the protruding structure of the arch support member during the hot pressing process; the pressing part is used to apply pressure to the heat-melted connection area between the cover layer and the sock body.

[0013] Compared with the prior art, the beneficial effects of the present invention include at least the following: 1. The present invention provides an avoidance structure on the bearing part or the high-temperature resistant elastic layer, so that at least part of the protruding structure of the arch support is entered or confined in the avoidance structure during the hot pressing process, which can reduce the risk of the support being crushed, deviated or deformed by hot pressing.

[0014] 2. The present invention can position the arch support component by means of avoidance structure, positioning line, positioning hole or limiting edge, which helps to improve the correspondence accuracy between the arch support component and the arch area of ​​the sock body.

[0015] 3. The present invention confines the arch support to the area enclosed by the cover layer and the sock body through the cover layer and the hot-melt bonding layer, which ensures a stable connection and reduces local curling, delamination and other phenomena.

[0016] 4. The hot-melt bonding layer of the present invention can adopt a closed-loop, open-loop, mesh, perforated, dot matrix, strip, or partially spaced structure, which can take into account the bonding strength, breathability, and wearing comfort. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the cross-sectional structure of an arch support sock; Figure 2 This is a schematic diagram of the hot pressing process for flat plates and the process of creating clearance holes. Figure 3 This is a schematic diagram of an optional hot pressing device with a pressing protrusion; Figure 4 This is a top view of the area where the arch support connects to the periphery; In the diagram: 1. Covering layer; 2. Hot-melt bonding layer or hot-melt bonding area; 3. Arch support; 4. Sock body; 5. Central avoidance area, non-connection area or breathable area; 6. Press-fit part; 7. Limiting block; 8. Press-fit protrusion or annular protrusion; 9. High-temperature resistant elastic layer; 10. Bearing part; 11. Avoidance structure; 12. Auxiliary adhesive layer; 13. Breathing holes. Detailed Implementation

[0018] The present invention will be further described below with reference to specific embodiments.

[0019] Example 1 A method for preparing arch support socks using a flatbed hot press and an open-cell high-temperature resistant elastic layer, such as... Figures 1-4 As shown, the procedure includes the following steps: First, preparing the sock body, arch support, cover layer, and hot melt bonding layer, wherein the cover layer is made of knitted fabric, meltblown fabric, non-woven fabric, or skin-friendly composite fabric; the arch support is a silicone elastic element or TPE elastic element with breathable holes; and the hot melt bonding layer is a TPU hot melt film, PES polyester hot melt adhesive film, PA hot melt film, EVA hot melt film, or a composite film layer thereof.

[0020] Second, a high-temperature resistant elastic layer is laid on the worktable of the bearing part. The high-temperature resistant elastic layer can be a high-temperature resistant silicone pad, a fluororubber layer, a heat-resistant rubber layer, or a polytetrafluoroethylene composite layer. A crescent-shaped clearance hole, adapted to the outer contour of the arch support, is pre-cut or formed on the high-temperature resistant elastic layer. The clearance hole can penetrate the high-temperature resistant elastic layer, or it can be a non-penetrating clearance groove or clearance cavity.

[0021] Third, lay the arch area of ​​the sock on the high-temperature resistant elastic layer, place the arch support component corresponding to the crescent-shaped clearance hole, and cover the outside of the arch support component with the cover layer, and the heat-fused bonding layer is located in the connection area between the cover layer and the sock body.

[0022] Fourth, start the flatbed hot press to lower the pressing section and hot press the arch support area of ​​the sock. During the hot pressing process, the protruding part of the arch support component, under the pressure of the hot pressing and the pressure transmitted by the sock body and the covering layer, at least partially enters the crescent-shaped clearance hole, preventing the protruding structure of the arch support component from being directly crushed; at the same time, the covering layer is bonded and fixed to the sock surface of the arch support area through a heat-fused bonding layer. The hot pressing parameters can be: hot pressing temperature 180℃ to 195℃, hot pressing time 10s to 15s. After hot pressing, cool and shape to obtain the arch support sock.

[0023] Example 2 Unlike Embodiment 1, in this embodiment, the clearance structure on the high-temperature resistant elastic layer is a blind groove or arc-shaped cavity formed on the surface of the high-temperature resistant elastic layer. The depth of the blind groove or arc-shaped cavity is 30% to 100% of the protrusion height of the arch support. During the hot pressing process, at least part of the protrusion structure of the arch support enters the blind groove or arc-shaped cavity to provide clearance space and limit the displacement of the arch support.

[0024] Example 3 Unlike Embodiment 1, in this embodiment, the pressing part is not a simple planar hot press plate, but has pressing protrusions corresponding to the hot-melt connection area. These pressing protrusions can be annular bosses, multi-segment bosses, strip-shaped bosses, dot matrix protrusions, or flexible pressing layers. A limiting block can also be provided at the position of the foot arch support member corresponding to the pressing part. During hot pressing, the limiting block abuts against, approaches, or lightly presses against the foot arch support member to limit its displacement and assist it in entering the avoidance structure. This solution is an optional improvement structure and does not limit the invention to using annular bosses or limiting blocks.

[0025] Example 4 The arch support sock structures formed in Examples 1 to 3 are as follows: Figure 1 , Figure 4 As shown, the sock includes a sock body 4, an arch support 3, a covering layer 1, and a heat-fused bonding layer 2. The sock body 4 has an arch area corresponding to the position of the human foot arch; the arch support 3 is disposed in the arch area of ​​the sock body 4, and the arch support 3 can be an arc-shaped protrusion, crescent-shaped, sheet-like, or irregularly shaped protrusion structure; the covering layer 1 covers the outside of the arch support 3; the heat-fused bonding layer 2 is disposed in the connection area between the covering layer 1 and the sock body 4, so that the covering layer 1 is bonded and fixed to the arch area of ​​the sock body 4. The arch support 3 can have multiple ventilation holes 13.

[0026] The heat-fused bonding layer 2 can be a closed-loop, open-loop, mesh, perforated, dot-matrix, strip, or partially spaced structure. When the heat-fused bonding layer 2 is a closed-loop or open-loop structure, a central clearance zone 5 can be formed in the corresponding area of ​​the arch support 3; when the heat-fused bonding layer 2 is a mesh or perforated structure, multiple breathable channels can be formed in the connection area to improve breathability and wearing comfort. An auxiliary adhesive layer 12 can also be provided between the covering layer 1 and the arch support 3. The auxiliary adhesive layer 12 can be dot-matrix, strip, mesh, perforated, or ring-shaped.

[0027] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for preparing arch support socks, characterized in that, Includes the following steps: Prepare a sock body, an arch support, a cover layer, and a heat-fused bonding layer; position the arch support in the arch area of ​​the sock body, and cover the outside of the arch support with the cover layer; place the heat-fused bonding layer in the connection area between the cover layer and the sock body; place the positioned sock body in a heat-pressing device, the heat-pressing device including a pressing part and a supporting part, the supporting part being provided with a high-temperature resistant elastic layer, the high-temperature resistant elastic layer having a clearance structure corresponding to the position of the arch support, the clearance structure including clearance holes, clearance grooves, or clearance cavities; during heat pressing, at least a portion of the protruding structure of the arch support enters or is confined within the clearance structure, the pressing part applies pressure to the connection area corresponding to the heat-fused bonding layer, causing the cover layer to bond to the arch area of ​​the sock body through the heat-fused bonding layer, and after cooling, form an arch support sock.

2. The method for preparing the arch support sock according to claim 1, characterized in that: The hot-melt bonding layer is at least distributed in the peripheral connection area of ​​the cover layer, and the hot-melt bonding layer is a closed-loop, open-loop, mesh, porous, dot matrix, strip, or locally spaced structure.

3. The method for preparing the arch support sock according to claim 1, characterized in that: The covering layer and the arch support are bonded together by means of adhesion, partial bonding, dot bonding, strip bonding, hot melt bonding, or non-adhesive covering.

4. The method for preparing the arch support sock according to claim 1, characterized in that: The avoidance structure is an avoidance hole that penetrates the high-temperature resistant elastic layer, or a blind groove, cavity, or irregular cavity formed on the surface of the high-temperature resistant elastic layer; the shape of the avoidance structure is adapted to the outer contour of the foot arch support.

5. The method for preparing the arch support sock according to claim 1, characterized in that: The depth of the avoidance structure is 30% to 120% of the height of the arch support protrusion.

6. The method for preparing the arch support sock according to claim 1, characterized in that: In the fourth step of hot pressing, the hot pressing temperature is 170℃ to 210℃, and the hot pressing time is 8s to 20s. After hot pressing is completed, the hot pressing area is subjected to pressure holding and cooling, natural cooling, air cooling, or cold pressing for shaping.

7. The method for preparing the arch support sock according to claim 1, characterized in that: Before hot pressing, the arch support is positioned in the arch area of ​​the sock body by means of positioning lines, positioning holes, limiting edges, positioning fixtures or visual positioning methods set on the high-temperature resistant elastic layer.

8. A type of arch support sock, characterized in that, include: The sock body has an arch area corresponding to the arch position of the human foot; An arch support member is disposed in the arch area of ​​the sock body. The arch support member is an arc-shaped, crescent-shaped, sheet-like, or irregularly shaped protruding structure adapted to the arch area. A cover layer covers the outside of the arch support member. A heat-fused bonding layer is disposed in the connection area between the cover layer and the sock body. The cover layer is heat-fused to the arch area of ​​the sock body through the heat-fused bonding layer. The arch support member is located in the area enclosed by the cover layer and the sock body, and the heat-fused bonding layer forms an avoidance area, a non-connection area, a weak connection area, or a breathable area in the corresponding area of ​​the arch support member.

9. The arch support sock according to claim 8, characterized in that: The arch support is molded from silicone, TPE, TPU, EVA, PU, ​​rubber, foamed elastic material, or composite elastic material.

10. The arch support sock according to claim 8, characterized in that: The foot arch support is provided with multiple ventilation holes, air guide grooves, weight reduction holes or flexible deformation grooves.

11. The arch support sock according to claim 8, characterized in that: The hot melt bonding layer is a TPU hot melt film, a PES polyester hot melt adhesive film, a PA hot melt film, an EVA hot melt film, or a composite film layer thereof; the covering layer is a meltblown fabric, a knitted fabric, a non-woven fabric, a mesh fabric, a microfiber fabric, a skin-friendly composite fabric, or a composite fabric layer.

12. The arch support sock according to claim 8, characterized in that: An auxiliary adhesive layer is provided between the covering layer and the arch support member. The auxiliary adhesive layer can be dot-shaped, strip-shaped, mesh-shaped, perforated, or ring-shaped.

13. A hot pressing device for preparing arch support socks, characterized in that, It includes a pressing part, a bearing part, and a high-temperature resistant elastic layer disposed on the bearing part; the high-temperature resistant elastic layer is provided with a relief structure corresponding to the position of the arch support member, the relief structure including a relief hole, a relief groove or a relief mold cavity, the relief structure is used to accommodate at least part of the protruding structure of the arch support member during the hot pressing process; the pressing part is used to apply pressure to the heat-melted connection area between the cover layer and the sock body.

14. The hot pressing device according to claim 13, characterized in that: The high-temperature resistant elastic layer is a high-temperature resistant silicone layer, a fluororubber layer, a polytetrafluoroethylene composite layer, a heat-resistant rubber layer, or other heat-resistant elastic material layers.

15. The hot pressing apparatus according to claim 13, characterized in that: The clearance structure is a crescent-shaped clearance hole penetrating the high-temperature resistant elastic layer, or an arc-shaped groove, crescent-shaped cavity, elliptical cavity, or irregular cavity adapted to the outer contour of the foot arch support formed on the surface of the high-temperature resistant elastic layer.

16. The hot pressing apparatus according to claim 13, characterized in that: The pressing part is a planar pressing plate, a flexible pressing plate, or a pressing plate with pressing protrusions; the pressing protrusions are annular protrusions, multi-segment protrusions, strip protrusions, dot matrix protrusions, or flexible pressing layers.

17. The hot pressing apparatus according to claim 16, characterized in that: The pressing part is provided with a limiting pressure block at the position corresponding to the arch support member. The limiting pressure block is used to abut, approach or lightly press the arch support member during hot pressing to limit the displacement of the arch support member and assist the arch support member in entering the avoidance structure.

18. The hot pressing apparatus according to claim 13, characterized in that: The high-temperature resistant elastic layer is provided with multiple avoidance structures, which are arranged in an array according to the sock placement position, and are used to position and avoid multiple socks or multiple arch support components in the same hot pressing process.

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