A wire-drawing air cushion, a sole applying the air cushion and a production process

Abstract

The application discloses a wire-drawing air cushion, a sole applying the air cushion and a production process, relates to the technical field of sole production, and comprises an air cushion body: the air cushion body comprises a shell and a wire-drawing cloth arranged in the shell, both ends of the wire-drawing cloth are compounded with hot melt connecting films, the hot melt connecting films are fixed with the inner wall of the shell, the wire-drawing cloth comprises a first woven cloth layer, a second woven cloth layer and a wire-drawing fiber layer, the wire-drawing fiber layer is arranged between the first woven cloth layer and the second woven cloth layer, the wire-drawing fiber layer comprises a plurality of wire-drawing fiber bundles, and each wire-drawing fiber bundle is differentially distributed in different regions of the wire-drawing cloth. The plurality of wire-drawing fiber bundles in the wire-drawing fiber layer are differentially distributed in different regions of the wire-drawing cloth, so that the problem that a traditional uniform distribution structure cannot simultaneously meet the different supporting requirements of different regions is effectively solved.

Description

Technical Field

[0001] This invention relates to the field of shoe sole manufacturing technology, specifically to a brushed air cushion, a shoe sole using the air cushion, and a manufacturing process thereof. Background Technology

[0002] Wire-stretched air cushions are a type of cushioning structure widely used in athletic shoes, casual shoes, and professional functional shoes. They consist of wire-stretched fabric placed within a sealed outer shell, with the upper and lower inner walls connected by the wire-stretched fibers. Upon inflation, this forms an air cushion cavity with a stable support height, providing excellent cushioning, shock absorption, and energy rebound for the shoe sole. Wire-stretched air cushions can also be applied to bag shock absorption, seat backs, and medical protective gear. The tension of the internal wire-stretched fibers maintains the stability of the inflated shape, effectively improving product comfort and lifespan. They offer advantages such as lightweight structure, adjustable cushioning performance, and high durability. Existing wire-stretched air cushions typically employ a structure with two layers of woven fabric sandwiching a middle layer of wire-stretched fibers. During inflation, the fibers are stretched into filaments, connecting and supporting the upper and lower outer shells. The outer shell generally has supporting protrusions and positioning recesses to define the final shape of the air cushion. After the air cushion is formed, it is inflated and sealed using inflatable protrusions.

[0003] In the long-term use of existing brushed air cushions, the brushed fiber layer of traditional brushed air cushions is evenly distributed in the fabric area, and the density of each fiber bundle is completely consistent. Although the vertically and evenly arranged brushed fibers can provide uniform support, they cannot provide differentiated support for the different stress requirements of different areas of the air cushion. For example, the heel area bears greater impact and requires higher density fiber support, while the forefoot area requires more flexible deformation response. The evenly distributed brushed fiber structure cannot take into account the support and cushioning needs of different areas, resulting in an unreasonable overall force distribution of the air cushion. After long-term use, the fibers in some areas are prone to premature fatigue or breakage, affecting the service life of the air cushion and the consistency of its cushioning performance. Summary of the Invention

[0004] This invention provides a wire-drawn air cushion, a shoe sole using the air cushion, and a manufacturing process to solve the problems mentioned in the background art.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A brushed air cushion, a shoe sole using the air cushion, and a manufacturing process are disclosed. The air cushion body includes an outer shell and a brushed fabric disposed within the outer shell. Both ends of the brushed fabric are laminated with a heat-fused connecting film, which is fixed to the inner wall of the outer shell. The brushed fabric includes a first woven layer, a second woven layer, and a brushed fiber layer. The brushed fiber layer is disposed between the first and second woven layers and includes multiple brushed fiber bundles, each with a differentiated density distribution in different areas of the brushed fabric. The outer shell includes supporting protrusions and positioning recesses. The supporting protrusions are located on the left and right sides of the outer shell, and the positioning recesses are located at the upper and lower ends of the outer shell. The front and rear ends of the outer shell are respectively provided with opening protrusions for inserting the brushed fabric and inflatable protrusions for inflation.

[0006] A further improvement of the technical solution of the present invention is that: the width between the upper and lower parts of the positioning recess is equal to the thickness of the filament fabric; the shape of the positioning recess is the same as the shape of the first woven layer and the second woven layer; the hot-melt bonding film is a low-temperature TPU hot-melt film; the outer shell is a high-temperature hollow TPU air cushion; the filament layer includes a first density region and a second density region; the density of the filament bundles in the first density region is greater than the density of the filament bundles in the second density region; the first density region is correspondingly located in the heel area of ​​the air cushion body; and the second density region is correspondingly located in the sole area of ​​the air cushion body.

[0007] A further improvement of the technical solution of the present invention is that: the drawn fiber bundle includes a first drawn fiber and a second drawn fiber, the first drawn fiber is disposed between the first woven layer and the second woven layer, the second drawn fiber is disposed at an inclination relative to the first drawn fiber between the first woven layer and the second woven layer, and the first drawn fiber and the second drawn fiber are distributed in a cross pattern to form an X-shaped support structure.

[0008] A further improvement of the technical solution of the present invention is that: the interior of the outer shell is further provided with an internal reinforcing rib, the internal reinforcing rib having a columnar structure, the upper end of the internal reinforcing rib being connected to the upper inner wall of the outer shell, the lower end of the internal reinforcing rib being connected to the lower inner wall of the outer shell, the material of the internal reinforcing rib being the same as that of the outer shell and being integrally formed with the outer shell, a first damping layer being provided between the first woven fabric layer and the drawn fiber layer, and a second damping layer being provided between the second woven fabric layer and the drawn fiber layer, the first damping layer and the second damping layer being high-damping elastomer material layers used to absorb high-frequency vibrations.

[0009] A further improvement of the technical solution of the present invention is that: the first damping layer and the second damping layer are made of silicone rubber or butyl rubber, the thickness of the first damping layer and the second damping layer is 0.3-1.5mm, the surface of the supporting protrusion is provided with anti-slip texture, the anti-slip texture is a plurality of spaced protrusions; the surface of the positioning recess is provided with a guide groove, the guide groove extends along the length direction of the positioning recess.

[0010] A further improvement to the technical solution of the present invention is that it includes the following steps: S1. Cut the drawing cloth and hot melt bonding film into the required shapes, and attach the two pieces of hot melt bonding film to the two end faces of the drawing cloth respectively. Press the hot melt bonding film with hot heat to make it slightly melt and fix it to the surface of the first and second fabric layers of the drawing cloth. After cooling, peel off the release paper on the hot melt bonding film. S2. The outer shell is integrally injection molded using an injection mold. During the injection molding process, internal reinforcing ribs are simultaneously formed inside the outer shell. After the outer shell cools, the wire drawing cloth with a hot melt bonding film is inserted into the inner cavity of the outer shell through the opening protrusion. The wire drawing cloth is clamped by the upper and lower positioning recesses, and the alignment of the wire drawing cloth is finely adjusted so that its edge is flush with the edge of the positioning recess. S3. Apply heat to the outer shell to make the heat-melting bonding film melt again and adhere and fix it to the inner wall of the positioning recess, so that the wire cloth is integrated with the inner wall of the outer shell. S4. Hot-press the opening bump to melt and seal the opening. After cooling, trim off the excess part of the opening bump. S5. Inflate the inner cavity of the outer shell through the inflatable protrusion and seal it with a high-frequency sealing machine. The outer shell expands under air pressure, and the filamentous layer is stretched into filaments. After cooling, trim the excess part of the inflatable protrusion to obtain the finished filamentous air cushion.

[0011] A further improvement to the technical solution of the present invention is as follows: In step S1, the temperature of the hot-pressed hot-melt bonding film is 80-120℃, and the hot-pressing time is 5-15s, so that the hot-melt bonding film reaches a slightly molten state and is fixed with the drawing cloth; in step S2, the temperature of the outer shell injection molding is 180-220℃, the injection pressure is 50-100MPa, and the inner cavity height of the outer shell after injection molding and cooling is greater than the thickness of the drawing cloth; in step S3, the temperature of the hot-pressed outer shell is 100-150℃, the hot-pressing time is 10-30s, and the hot-pressing pressure is 0.5-2MPa, so that the hot-melt bonding film is slightly molten again and adheres to the inner wall of the positioning recess; in step S5, the inflation pressure is 0.3-1.0MPa, the frequency of high-frequency sealing is 30-80MHz, and the sealing time is 2-8s.

[0012] A further improvement of the technical solution of the present invention is that the wire-drawn air cushion is located in the middle of the heel of the main body of the shoe sole.

[0013] A further improvement to the technical solution of the present invention is that it includes the following steps: S1. The fabrication process of the present invention is used to prepare the wire-drawing air cushion. The prepared wire-drawing air cushion is placed on the support column of the shoe sole mold, so that the support protrusion of the wire-drawing air cushion faces upward and is positioned at the predetermined position of the mold cavity. S2. Cover the shoe sole mold and inject the shoe sole material into the mold cavity. The injection temperature is 180-240℃ and the injection pressure is 60-120MPa, so that the shoe sole material wraps around the outer periphery of the wire-drawn air cushion. S3. After cooling, open the mold, remove the sole, and obtain the finished sole with the brushed air cushion being integrally wrapped and fixed by the sole material. In step S2, the sole material is any one of EVA foam, TPU, or rubber.

[0014] A further improvement to the technical solution of the present invention is that it includes the following steps: S1. A wire-drawn air cushion is prepared using the manufacturing process of the present invention; S2. The main body of the shoe sole is prepared by injection molding using an injection mold, and an installation groove for installing the wire-drawing air cushion is integrally formed at the base of the main body of the shoe sole. S3. Apply adhesive to the inner wall of the mounting groove, embed the wire-drawn air cushion into the mounting groove and press it into position, so that the wire-drawn air cushion is bonded and fixed to the main body of the shoe sole as one piece. In step S2, the shape of the mounting groove of the sole body is adapted to the shape of the outer shell of the brushed air cushion, and the depth of the mounting groove is equal to 1 / 3 to 1 / 2 of the thickness of the brushed air cushion. In step S3, the adhesive is a PU adhesive or a water-based polyurethane adhesive, the amount of adhesive applied is 80-150 g / m², the pressing pressure is 0.3-0.8 MPa, and the pressing time is 10-30 s.

[0015] Due to the adoption of the above technical solution, the technical progress achieved by this invention compared to the prior art is as follows: This invention provides a brushed fiber air cushion, a shoe sole using this air cushion, and a manufacturing process. By distributing multiple brushed fiber bundles in different areas of the brushed fabric with differentiated densities within the brushed fiber layer, it effectively solves the problem that traditional uniformly distributed structures cannot simultaneously meet the differentiated support needs of different areas. Specifically, the brushed fiber layer includes a first density region and a second density region. The density of the brushed fiber bundles in the first density region is greater than that in the second density region. The first density region is located in the heel area of ​​the air cushion body to provide higher density fiber support. The heel area bears a large impact load during exercise, and the high-density fiber bundles can effectively resist compression deformation and provide sufficient support. The second density region is located in the forefoot area of ​​the air cushion body, where a more flexible deformation response is required to adapt to the foot. The bending and propulsion movements, along with the lower density fiber distribution, provide greater deformation space and cushioning flexibility in the foot area, thereby enabling precise control of the support performance in different areas of the air cushion and making the overall force distribution more reasonable. At the same time, the drawn fiber bundle includes a first drawn fiber and a second drawn fiber. The first drawn fiber is vertically arranged between the first and second woven fabric layers, while the second drawn fiber is inclined relative to the first drawn fiber. The two are distributed in an X-shaped support structure. When subjected to compressive loads, the X-shaped structure can decompose the vertical pressure into a horizontal component, effectively improving the compressive strength and shear resistance of the drawn fiber layer. This avoids premature fatigue fracture of the fibers due to stress concentration under long-term cyclic loads, significantly extending the service life of the air cushion and ensuring the long-term consistency of cushioning performance. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the air-cushioned shoe sole of the present invention; Figure 2 This is a cross-sectional view of the wire-drawing air cushion of the present invention; Figure 3 This is a schematic diagram of the exploded structure of the wire-drawing air cushion of the present invention. Figure 1 Figure 4 This is a schematic diagram of the exploded structure of the wire-drawing air cushion of the present invention. Figure 2 ; Figure 5 This is an exploded structural diagram of the drawing fabric of the present invention.

[0017] In the diagram: 1. Air cushion body; 2. Outer shell; 3. Brushed fabric; 4. Hot melt bonding film; 5. First woven fabric layer; 6. Second woven fabric layer; 7. Brushed fiber layer; 8. Supporting protrusion; 9. Positioning recess; 10. Opening protrusion; 11. Inflatable protrusion; 12. Outsole body; 13. Internal reinforcing rib; 14. First damping layer; 15. Second damping layer; 16. Anti-slip texture; 17. Guide channel. Detailed Implementation

[0018] The present invention will be further described in detail below with reference to embodiments: Example 1, as Figures 1-5 As shown, this invention provides a brushed fabric air cushion, including an air cushion body 1. The air cushion body 1 includes a shell 2 and a brushed fabric 3 disposed within the shell 2. The shell 2 serves as the outer sealing shell of the air cushion, used to wrap and accommodate the brushed fabric 3 and provide a supporting shape. The brushed fabric 3 serves as the internal core support structure of the air cushion, used to connect the upper and lower inner walls of the shell 2 and provide a stable support height after inflation. Both ends of the brushed fabric 3 are laminated with a heat-fused connecting film 4, which is used to bond and fix the two ends of the brushed fabric 3 to the inner wall of the shell 2. The heat-fused connecting film 4 is fixed to the inner wall of the shell 2. The brushed fabric 3 includes a first woven layer 5, a second woven layer 6, and a brushed fiber layer 7. The first woven layer 5 serves as the upper base fabric of the brushed fabric 3, used to fix the upper end of the brushed fiber layer 7. The second woven layer 6 serves as the lower base fabric of the brushed fabric 3, used to fix the lower end of the brushed fiber layer 7. The brushed fiber layer 7 is disposed between the first woven layer 5 and the second woven layer 6. Between the fabric layers 6, the fiber layer 7 is an array of fiber bundles connecting the upper and lower fabric layers, which is used to form a support column structure after inflation; the fiber layer 7 includes multiple fiber bundles, and each fiber bundle has a differentiated density distribution in different areas of the fiber fabric 3, which is used to provide differentiated support force for different stress requirements in different areas; the outer shell 2 includes a support protrusion 8 and a positioning recess 9. The support protrusion 8 is located on the left and right sides of the outer shell 2, which is used to support and strengthen the lateral side of the outer shell 2 and form an anti-slip structure. The positioning recess 9 is located at the upper and lower ends of the outer shell 2, which is used to clamp and position the fiber fabric 3 during assembly; the front and rear ends of the outer shell 2 are respectively provided with an opening protrusion 10 for inserting the fiber fabric 3 and an inflation protrusion 11 for inflation. The opening protrusion 10 serves as a channel for inserting the fiber fabric 3 into the inner cavity of the outer shell 2 and is closed after hot pressing. The inflation protrusion 11 serves as an inflation channel for inflating gas into the inner cavity of the outer shell 2.

[0019] The width between the upper and lower positioning recesses 9 is equal to the thickness of the drawing cloth 3, which is used to ensure the positioning accuracy of the drawing cloth 3 when it is clamped by the upper and lower positioning recesses 9. The shape of the positioning recesses 9 is the same as the shape of the first fabric layer 5 and the second fabric layer 6, which is used to completely fit the edge of the drawing cloth 3 to ensure positioning accuracy. The hot melt bonding film 4 is set as a low-temperature TPU hot melt film. The low-temperature TPU hot melt film has a lower melting temperature to reduce thermal damage to the drawing cloth 3 during hot pressing. The outer shell 2 is set as a high-temperature hollow TPU air cushion. The high-temperature TPU has a higher melting temperature. To ensure that the outer shell 2 maintains shape stability during subsequent hot pressing processes; the drawn fiber layer 7 includes a first density region and a second density region. The density of the drawn fiber bundles in the first density region is greater than that in the second density region, which is used to provide stronger support in areas with greater stress; the first density region is located in the heel area of ​​the air cushion body 1, and the second density region is located in the toe area of ​​the air cushion body 1. The heel area bears a larger impact load during movement and requires higher density support, while the toe area requires a more flexible deformation response to adapt to foot bending and propulsion movements.

[0020] The drawn fiber bundle includes a first drawn fiber and a second drawn fiber. The first drawn fiber is disposed between the first woven layer 5 and the second woven layer 6 to provide vertical support. The second drawn fiber is disposed at an angle relative to the first drawn fiber between the first woven layer 5 and the second woven layer 6 to provide oblique support to enhance shear resistance. The first and second drawn fibers are distributed in a cross pattern to form an X-shaped support structure. The X-shaped support structure can decompose vertical pressure into horizontal components, effectively improving the compressive strength and structural stability of the drawn fiber layer 7.

[0021] The outer shell 2 also has an internal reinforcing rib 13, which is columnar in structure and is used to provide additional support points inside the air cushion to control the expansion shape after inflation. The upper end of the internal reinforcing rib 13 is connected to the upper inner wall of the outer shell 2, and the lower end of the internal reinforcing rib 13 is connected to the lower inner wall of the outer shell 2 to limit the excessive expansion height of the outer shell 2 during inflation. The material of the internal reinforcing rib 13 is the same as that of the outer shell 2 and is integrally formed with the outer shell 2 to ensure the connection strength between the internal reinforcing rib 13 and the outer shell 2. A first damping layer 14 is provided between the first woven fabric layer 5 and the drawn fiber layer 7, and a second damping layer 15 is provided between the second woven fabric layer 6 and the drawn fiber layer 7. The first damping layer 14 and the second damping layer 15 are high-damping elastomer material layers to absorb high-frequency vibrations and effectively filter high-frequency shock waves from the ground.

[0022] The first damping layer 14 and the second damping layer 15 are made of silicone rubber or butyl rubber. Silicone rubber and butyl rubber have excellent high damping characteristics and fatigue resistance, and are used to form a buffer layer between the fiber layer 7 and the fabric layer. The thickness of the first damping layer 14 and the second damping layer 15 is 0.3-1.5mm. This thickness range can ensure the damping effect while avoiding excessive increase in the overall thickness of the air cushion. The surface of the supporting protrusion 8 is provided with anti-slip texture 16, which consists of multiple spaced convex strips, used to increase the friction between the supporting protrusion 8 and the sole material to prevent the air cushion from sliding inside the sole. The surface of the positioning recess 9 is provided with a guide groove 17, which extends along the length of the positioning recess 9, used to guide air bubbles out during hot pressing to improve the bonding quality between the hot melt bonding film 4 and the inner wall of the positioning recess 9.

[0023] In this embodiment, by distributing multiple fiber bundles in the fiber layer 7 at different densities in different areas of the fiber fabric 3, the heel and foot areas receive fiber support of different densities, effectively solving the problem that traditional uniform distribution structures cannot meet the differentiated support needs of different areas, and achieving precise control of the support performance of different areas of the air cushion; by forming an X-shaped support structure through the cross distribution of the first and second fiber bundles, the compressive strength and shear resistance of the fiber layer 7 are significantly improved, avoiding premature fatigue fracture of the fibers due to stress concentration under long-term cyclic loads; by absorbing high-frequency vibrations through the first damping layer 14 and the second damping layer 15, the damage of high-frequency impacts to the fiber bundles is effectively reduced; and by limiting the inflation height of the outer shell 2 through the internal reinforcing ribs 13, the high stability and structural integrity of the air cushion during long-term use are ensured.

[0024] Example 2, as Figures 1-4 As shown, based on Embodiment 1, the present invention provides a technical solution: Preferably, the manufacturing process of the wire-drawn air cushion includes the following steps: S1. Cut the filament fabric 3 and the hot melt bonding film 4 into the required shapes, and attach the two pieces of hot melt bonding film 4 to the two end faces of the filament fabric 3 respectively. The temperature of the hot melt bonding film 4 is 80-120℃ and the time is 5-15s, so that the hot melt bonding film 4 reaches a slightly melted state and is fixed to the surface of the first fabric layer 5 and the second fabric layer 6 of the filament fabric 3. The temperature range of 80-120℃ can make the low temperature TPU hot melt film melt evenly and slightly without excessive melting and penetration into the filament fiber layer 7. The hot pressing time of 5-15s ensures that the hot melt bonding film 4 and the fabric layer form sufficient initial bonding strength. After cooling, peel off the release paper on the hot melt bonding film 4 to expose the bonding surface of the hot melt bonding film 4 for subsequent bonding to the inner wall of the outer shell 2. S2. The outer shell 2 is integrally injection molded using an injection mold. The injection molding temperature is 180-220℃ and the pressure is 50-100MPa. This temperature range allows the high-temperature TPU material to fully melt and flow and fill the mold cavity. This pressure range ensures the molding density and dimensional accuracy of the outer shell 2. During the injection molding process, internal reinforcing ribs 13 are simultaneously formed inside the outer shell 2, realizing the integral molding of the outer shell 2 and the internal reinforcing ribs 13 to simplify the process and improve the connection strength. After the outer shell 2 is cooled by injection molding, the height of the inner cavity is greater than the thickness of the drawing cloth 3, leaving sufficient assembly gap for the insertion of the drawing cloth 3. After the outer shell 2 cools, the drawing cloth 3 with the hot melt connecting film 4 is inserted into the inner cavity of the outer shell 2 through the opening protrusion 10, so that the drawing cloth 3 is clamped by the upper and lower positioning recesses 9, and the drawing cloth 3 is finely adjusted and aligned so that its edge is flush with the edge of the positioning recesses 9, ensuring the positional accuracy of the drawing cloth 3 inside the outer shell 2. S3. Hot-press the outer shell 2 at a temperature of 100-150℃ for 10-30 seconds and a pressure of 0.5-2MPa. This causes the hot-melt bonding film 4 to melt again and bond and fix it to the inner wall of the positioning recess 9. The temperature of 100-150℃ allows the low-temperature TPU hot-melt film to melt again without causing thermal deformation to the outer shell 2. The hot-pressing time of 10-30 seconds ensures full fusion of the bonding interface. The hot-pressing pressure of 0.5-2MPa ensures tight contact of the bonding interface, so that the filament cloth 3 is integrated with the inner wall of the outer shell 2. S4. Hot-press the opening protrusion 10 to melt and seal the opening. After cooling, trim the excess part of the opening protrusion 10 to form a complete sealed cavity in the outer shell 2. S5. Inflate the inner cavity of the outer shell 2 through the inflatable protrusion 11 at an inflation pressure of 0.3-1.0 MPa, and seal it with a high-frequency sealing machine at a frequency of 30-80 MHz and a time of 2-8 seconds. The inflation pressure range allows the outer shell 2 to expand fully and ensures that the filament layer 7 is completely stretched into a filament. The frequency and time of the high-frequency sealing ensure full fusion and sealing of the sealing part. The outer shell 2 expands under air pressure, and the filament layer 7 is stretched into a filament. After cooling, trim the excess part of the inflatable protrusion 11 to obtain the finished filament air cushion.

[0025] In this embodiment, the integrated injection molding of the outer shell 2 and the internal reinforcing rib 13 in step S2 simplifies the manufacturing process and enhances the structural strength of the outer shell 2. Through the precise control of process parameters in steps S1 to S5, the bonding strength between the hot melt bonding film 4 and the drawing cloth 3 and the inner wall of the outer shell 2, the molding accuracy of the outer shell 2, and the complete stretching and molding of the drawing fiber layer 7 after inflation are ensured, thus realizing the high-quality mass production of the drawing air cushion.

[0026] Example 3, as Figures 1-4As shown, based on Embodiment 1, the present invention provides a technical solution: Preferably, an air-cushioned shoe sole includes a sole body 12 and the aforementioned brushed air cushion. The sole body 12 serves as the basic structure of the sole to support the brushed air cushion and contact the ground. The brushed air cushion is located in the middle of the heel of the sole body 12 to provide cushioning and shock absorption in the heel area of ​​the sole. The middle of the heel is the main force-bearing area when the heel strikes the ground during exercise. The brushed air cushion located in this position can achieve the best shock absorption effect in the position where cushioning is most needed.

[0027] In this embodiment, by placing the wire-stretched air cushion in the middle of the heel of the sole body 12, the cushioning function of the air cushion is concentrated in the heel impact area, effectively absorbing the impact of landing while reasonably controlling the area and cost of the air cushion.

[0028] Example 4, as Figures 1-4 As shown, based on Embodiment 1, the present invention provides a technical solution: preferably, a manufacturing process for an air-cushioned shoe sole includes the following steps: S1. The aforementioned manufacturing process is used to prepare the wire-drawing air cushion. The prepared wire-drawing air cushion is placed on the pre-set support column of the shoe sole mold, so that the support protrusion 8 of the wire-drawing air cushion faces upward and is positioned at the predetermined position of the mold cavity. The support column is used to support and fix the wire-drawing air cushion during the injection molding process to prevent it from shifting under the injection pressure. S2. Cover the shoe sole mold and inject shoe sole material into the mold cavity. The injection temperature is 180-240℃ and the pressure is 60-120MPa. This temperature range allows the shoe sole material to fully melt and flow and wrap around the outer periphery of the brushed air cushion. This pressure range ensures the molding density of the shoe sole material and the tightness of its wrapping with the brushed air cushion, so that the shoe sole material tightly wraps around the outer periphery of the brushed air cushion. S3. After cooling, open the mold, remove the sole, and obtain the finished sole with the brushed air cushion integrally wrapped and fixed by the sole material. The sole material can be any one of EVA foam material, TPU material or rubber material. EVA foam material is lightweight and soft and is suitable for casual shoe soles. TPU material has high elasticity and high wear resistance and is suitable for sports shoe soles. Rubber material has excellent anti-slip and aging resistance and is suitable for outdoor shoe soles.

[0029] In this embodiment, by placing the brushed air cushion inside the sole mold and integrally injection molding it with the sole material, the brushed air cushion is completely wrapped and fixed by the sole material, achieving a stable bond between the brushed air cushion and the sole, avoiding the delamination problem that may occur in subsequent bonding processes, and simplifying the manufacturing process of the sole.

[0030] Example 5, as Figures 1-4As shown, based on Embodiment 1, the present invention provides a technical solution: preferably, a manufacturing process for an air-cushioned shoe sole includes the following steps: S1. Prepare the drawn air cushion using the aforementioned manufacturing process; S2. The sole body 12 is prepared by injection molding. An installation groove for installing the brushed air cushion is integrally formed at the root of the sole body 12. The installation groove is used to accommodate and position the brushed air cushion. The shape of the installation groove of the sole body 12 is adapted to the shape of the shell 2 of the brushed air cushion to ensure that the air cushion can be accurately embedded. The depth of the installation groove is equal to 1 / 3 to 1 / 2 of the thickness of the brushed air cushion. This depth range can ensure that there is sufficient contact area between the air cushion and the installation groove while allowing part of the thickness of the air cushion to be exposed on the sole surface so as to directly contact the foot and play a cushioning function. S3. Apply adhesive to the inner wall of the mounting groove, embed the wire-drawn air cushion into the mounting groove, and press and position it. The adhesive is PU adhesive or water-based polyurethane adhesive. PU adhesive has excellent bonding strength and aging resistance, while water-based polyurethane adhesive has the advantages of being environmentally friendly and solvent-free. The amount of adhesive applied is 80-150g / m². This amount of adhesive can ensure that a uniform adhesive layer is formed between the inner wall of the mounting groove and the outer shell 2 of the wire-drawn air cushion without overflowing adhesive. The pressing pressure is 0.3-0.8MPa and the pressing time is 10-30s. This pressing condition can ensure that the adhesive fully wets the bonding interface and forms sufficient initial bonding strength, so that the wire-drawn air cushion and the main body 12 of the shoe sole are bonded and fixed together.

[0031] In this embodiment, by separately injection molding the main body 12 of the sole and then bonding and installing the brushed air cushion, it is convenient to flexibly configure brushed air cushions of different specifications for different sole styles, reducing the complexity of mold development and manufacturing costs. By controlling the depth of the mounting groove to 1 / 3 to 1 / 2 of the thickness of the brushed air cushion, the air cushion is exposed on the sole surface, which is conducive to giving full play to the cushion's cushioning deformation capacity and energy rebound effect. By coating and bonding with PU adhesive or water-based polyurethane adhesive, the brushed air cushion is reliably fixed to the main body 12 of the sole, ensuring that the air cushion will not fall off or shift during long-term use.

[0032] The following section will explain in detail the working principle of the brushed air cushion, the shoe sole using the air cushion, and the manufacturing process.

[0033] like Figures 1-5As shown, during the manufacturing process of this brushed air cushion, a low-temperature TPU hot-melt bonding film 4 is first bonded to both ends of the brushed cloth 3 using low-temperature hot pressing to form a pre-fabricated composite. Then, a high-temperature TPU shell 2 is injection molded at a temperature of 180-220℃, and columnar internal reinforcing ribs 13 are simultaneously formed inside the shell 2. After the shell 2 cools, the brushed cloth 3 is inserted into the inner cavity of the shell 2 through the opening protrusion 10. The edges of the brushed cloth 3 are clamped and positioned by the upper and lower positioning recesses 9. Then, the shell 2 is hot-pressed, causing the low-temperature TPU hot-melt bonding film 4 to melt again and bond and fix to the inner wall of the positioning recesses 9, thus achieving a firm bond between the brushed cloth 3 and the inner wall of the shell 2. Subsequently, the opening protrusion 10 is sealed by hot pressing, and gas of 0.3-1.0 MPa is injected into the inner cavity of the outer shell 2 through the inflatable protrusion 11. Under the action of air pressure, the outer shell 2 expands, and the internal height increases. The filament bundles in the filament fiber layer 7 are stretched and extended into filaments, forming a support column array connecting the first fabric layer 5 and the second fabric layer 6. The first density area forms high-density support in the heel area, and the second density area forms low-density flexible support in the sole area. At the same time, the X-shaped structure of the first and second filament fibers cross-distributed provides excellent compressive and shear resistance. The internal reinforcing ribs 13 limit the excessive expansion of the outer shell 2 to maintain a stable support height. After high-frequency sealing, the inflatable protrusion 11 is trimmed to obtain the finished filament air cushion.

[0034] When applied to the sole, the brushed air cushion can be integrated with the sole in two ways: First, the brushed air cushion is placed in the sole mold, and sole materials such as EVA, TPU, or rubber are injected, so that the air cushion is integrally wrapped and fixed by the sole material; Second, the sole body 12 is injection molded separately, and an installation groove is reserved at the heel. After applying adhesive to the installation groove, the brushed air cushion is embedded and pressed to fix it. When worn, the impact force of the heel landing is transmitted to the outer shell 2 through the sole. The compression of the outer shell 2 causes the brushed fiber layer 7 to bear pressure. The X-shaped cross-distributed brushed fibers decompose the vertical pressure into horizontal components. The high-density fibers in the first density zone provide the strong support required by the heel area, and the low-density fibers in the second density zone provide flexible deformation response for the forefoot area. The first damping layer 14 and the second damping layer 15 absorb high-frequency vibrations, and the internal reinforcing ribs 13 maintain the height stability of the air cushion, thereby providing stable, comfortable, and durable cushioning protection for the foot and effectively extending the service life of the air cushion.

[0035] The present invention has been described in detail above. However, modifications or improvements can be made to it, which will be obvious to those skilled in the art. Therefore, any modifications or improvements that do not depart from the spirit of the present invention are within the scope of protection of the present invention.

Claims

1. A brushed air cushion, characterized in that: The air cushion body (1) includes an outer shell (2) and a filament fabric (3) disposed within the outer shell (2). Both ends of the filament fabric (3) are laminated with a heat-fused bonding film (4), which is fixed to the inner wall of the outer shell (2). The filament fabric (3) includes a first woven layer (5), a second woven layer (6), and a filament fiber layer (7). The filament fiber layer (7) is disposed between the first woven layer (5) and the second woven layer (6). The dimensional layer (7) includes multiple fiber bundles, and each fiber bundle has a differentiated density distribution in different areas of the fiber cloth (3); the outer shell (2) includes a support protrusion (8) and a positioning recess (9). The support protrusion (8) is located on the left and right sides of the outer shell (2), and the positioning recess (9) is located at the upper and lower ends of the outer shell (2). The front and rear ends of the outer shell (2) are respectively provided with an opening protrusion (10) for inserting the fiber cloth (3) and an inflatable protrusion (11) for inflation.

2. The brushed air cushion according to claim 1, characterized in that: The width between the upper and lower parts of the positioning recess (9) is equal to the thickness of the filament fabric (3). The shape of the positioning recess (9) is the same as the shape of the first woven layer (5) and the second woven layer (6). The hot melt bonding film (4) is set as a low-temperature TPU hot melt film. The outer shell (2) is set as a high-temperature hollow TPU air cushion. The filament fiber layer (7) includes a first density area and a second density area. The density of the filament fiber bundle in the first density area is greater than the density of the filament fiber bundle in the second density area. The first density area is correspondingly set in the heel area of ​​the air cushion body (1), and the second density area is correspondingly set in the sole area of ​​the air cushion body (1).

3. The brushed air cushion according to claim 2, characterized in that: The fiber bundle includes a first fiber and a second fiber. The first fiber is disposed between the first fabric layer (5) and the second fabric layer (6). The second fiber is disposed at an angle relative to the first fiber between the first fabric layer (5) and the second fabric layer (6). The first fiber and the second fiber are distributed in an X-shaped support structure.

4. The brushed air cushion according to claim 3, characterized in that: The shell (2) is also provided with an internal reinforcing rib (13). The internal reinforcing rib (13) has a columnar structure. The upper end of the internal reinforcing rib (13) is connected to the upper inner wall of the shell (2), and the lower end of the internal reinforcing rib (13) is connected to the lower inner wall of the shell (2). The material of the internal reinforcing rib (13) is the same as that of the shell (2) and is integrally formed with the shell (2). A first damping layer (14) is provided between the first woven fabric layer (5) and the drawn fiber layer (7). A second damping layer (15) is provided between the second woven fabric layer (6) and the drawn fiber layer (7). The first damping layer (14) and the second damping layer (15) are high-damping elastomer material layers used to absorb high-frequency vibrations.

5. A brushed air cushion according to claim 4, characterized in that: The first damping layer (14) and the second damping layer (15) are made of silicone rubber or butyl rubber. The thickness of the first damping layer (14) and the second damping layer (15) is 0.3-1.5mm. The surface of the supporting protrusion (8) is provided with anti-slip texture (16), which is a plurality of spaced protrusions. The surface of the positioning recess (9) is provided with a guide groove (17), which extends along the length direction of the positioning recess (9).

6. A manufacturing process for a brushed air cushion, used to prepare a brushed air cushion as described in any one of claims 1-5, characterized in that, Includes the following steps: S1. Cut the drawing cloth (3) and the hot melt bonding film (4) into the required shape, and attach the two pieces of hot melt bonding film (4) to the two end faces of the drawing cloth (3) respectively. Press the hot melt bonding film (4) with hot heat to make it slightly melt and fix it to the surface of the first fabric layer (5) and the second fabric layer (6) of the drawing cloth (3). After cooling, peel off the release paper on the hot melt bonding film (4). S2. The outer shell (2) is integrally injection molded by injection molding. During the injection molding process, internal reinforcing ribs (13) are formed inside the outer shell (2). After the outer shell (2) cools down, the wire cloth (3) with the hot melt bonding film (4) is inserted into the inner cavity of the outer shell (2) through the opening protrusion (10), so that the wire cloth (3) is clamped by the upper and lower positioning recesses (9), and the wire cloth (3) is finely adjusted and aligned so that its edge is flush with the edge of the positioning recesses (9). S3. Apply heat to the outer shell (2) to make the heat-melting bonding film (4) melt again and bond and fix it to the inner wall of the positioning recess (9), so that the wire cloth (3) and the inner wall of the outer shell (2) are integrated. S4. Hot press the opening protrusion (10) to melt and seal the opening. After cooling, trim the excess part of the opening protrusion (10). S5. Inflate the inner cavity of the outer shell (2) through the inflatable protrusion (11) and seal it with a high-frequency sealing machine. The outer shell (2) expands under the action of air pressure, and the filament layer (7) is stretched into filament. After cooling, trim the excess part of the inflatable protrusion (11) to obtain the finished filament air cushion.

7. The manufacturing process of a brushed air cushion according to claim 6, characterized in that: In step S1, the temperature of the hot-pressed hot-melt bonding film (4) is 80-120℃, and the hot-pressing time is 5-15s, so that the hot-melt bonding film (4) reaches a slightly molten state and is fixed with the drawing cloth (3). In step S2, the temperature of the outer shell (2) injection molding is 180-220℃, the injection pressure is 50-100MPa, and the height of the inner cavity of the outer shell (2) after injection molding and cooling is greater than the thickness of the drawing cloth (3). In step S3, the temperature of the hot-pressed outer shell (2) is 100-150℃, the hot-pressing time is 10-30s, and the hot-pressing pressure is 0.5-2MPa, so that the hot-melt bonding film (4) is slightly molten again and is bonded to the inner wall of the positioning recess (9). In step S5, the inflation pressure is 0.3-1.0MPa, the frequency of high-frequency sealing is 30-80MHz, and the sealing time is 2-8s.

8. An air-cushioned shoe sole, characterized in that: The shoe includes a sole body (12) and a brushed air cushion as described in any one of claims 1-7, wherein the brushed air cushion is disposed at the middle position of the heel of the sole body (12).

9. A manufacturing process for an air-cushioned shoe sole, used to prepare an air-cushioned shoe sole comprising a brushed air cushion as described in any one of claims 1-5, characterized in that, Includes the following steps: S1. The fabrication process described in any one of claims 6-7 is used to prepare the fabricated air cushion. The prepared fabricated air cushion is placed on the support column of the shoe sole mold, so that the support protrusion (8) of the fabricated air cushion faces upward and is positioned at the predetermined position of the mold cavity. S2. Cover the shoe sole mold and inject the shoe sole material into the mold cavity. The injection temperature is 180-240℃ and the injection pressure is 60-120MPa, so that the shoe sole material wraps around the outer periphery of the wire-drawn air cushion. S3. After cooling, open the mold, remove the sole, and obtain the finished sole with the brushed air cushion being integrally wrapped and fixed by the sole material. In step S2, the sole material is any one of EVA foam, TPU, or rubber.

10. A manufacturing process for an air-cushioned shoe sole, used to prepare an air-cushioned shoe sole comprising a brushed air cushion as described in any one of claims 1-5, characterized in that, Includes the following steps: S1. A wire-drawn air cushion is prepared using the manufacturing process described in any one of claims 6-7; S2. The sole body (12) is prepared by injection molding separately using an injection mold. An installation groove for installing a wire-drawing air cushion is integrally formed at the root of the sole body (12). S3. Apply adhesive to the inner wall of the mounting groove, embed the wire-drawing air cushion into the mounting groove and press it into position so that the wire-drawing air cushion is bonded and fixed to the main body of the shoe sole (12) as one piece. In step S2, the shape of the mounting groove of the sole body (12) is adapted to the shape of the shell (2) of the brushed air cushion, and the depth of the mounting groove is equal to 1 / 3 to 1 / 2 of the thickness of the brushed air cushion. In step S3, the adhesive is a PU adhesive or a water-based polyurethane adhesive, the amount of adhesive applied is 80-150 g / m², the pressing pressure is 0.3-0.8 MPa, and the pressing time is 10-30 s.

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