Carbon fiber sole structure
By using multi-layer carbon fiber sheets and a V-shaped central support layer design, combined with foam filling and arch support patches, the problem of uneven rigidity and insufficient comfort of carbon fiber bicycle soles is solved, achieving all-round support and cushioning, and improving riding efficiency and comfort.
Patent Information
- Application Number
- CN202520653200.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-09
- Publication Date
- 2026-02-17
- Estimated Expiration
- 2035-04-09
AI Technical Summary
Existing carbon fiber bicycle soles suffer from uneven rigidity distribution, insufficient torsional resistance, lack of optimized comfort, and inadequate cushioning structure, resulting in uneven force distribution on the feet during riding and affecting riding efficiency and comfort.
Multi-layer carbon fiber sheets are stacked at different angles, combined with a V-shaped central support layer and foam filling, to design an arch support patch and a covering layer, forming a multi-angle support structure that increases torsional resistance and cushioning function.
It provides all-around rigid support, reduces vibration, improves comfort and durability, reduces weight, enhances torsional resistance, avoids localized deformation, and improves the riding experience.
Smart Images
Figure CN223913556U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to a shoe sole, specifically a carbon fiber shoe sole structure, which is particularly suitable for use by users of bicycles. Background Technology
[0002] To meet users' needs in different situations, shoes with different performance characteristics are available. Suitable shoes can make users more comfortable and relaxed. For example, when cycling, the rigidity and comfort of the shoe are key factors affecting cycling efficiency and experience. Traditional bicycle shoe sole materials mainly include plastics, glass fiber reinforced plastics (GFRP), and carbon fiber reinforced plastics (CFRP). Among them, carbon fiber is widely used in the high-end bicycle shoe market due to its excellent specific strength and specific stiffness. However, the current manufacturing methods of carbon fiber soles still have certain limitations, mainly reflected in the single carbon fiber layup method, relatively heavy weight, insufficient control of stiffness direction, limited torsional resistance, and lack of optimized comfort.
[0003] Currently, carbon fiber bicycle soles on the market typically use the following layering methods:
[0004] 1、 Unidirectional layup: Carbon fibers are laid primarily along the long axis of the foot (0°) to provide longitudinal rigidity, but lack lateral support and torsional resistance.
[0005] 2、 Cross-lay: Using 0° / 90° cross-lay improves the lateral rigidity of the sole, but because the biomechanical structure of the foot is not considered, it may lead to uneven local stress.
[0006] 3、 Quasi-isotropic layup: Combining angles of 0° / 45° / -45° / 90° makes the rigidity distribution more uniform, but it is still not optimized for the anatomical characteristics of the foot and cannot take into account the different support needs of different foot areas.
[0007] In addition, traditional carbon fiber soles mainly use a layered curing process, the main characteristics of which include:
[0008] 1. Single-layer method: Carbon fiber layers at different angles are stacked in sequence and cured under high temperature and pressure. However, due to the lack of local reinforcement structure, although the overall rigidity of the sole is high, local support is insufficient, especially in the arch area.
[0009] 2. Lack of local adjustable support: The existing sole structure lacks reinforcement design for specific parts such as the arch and metatarsals, resulting in insufficient foot stability, which may lead to fatigue or injury during long-term cycling.
[0010] 3. Comfort issues: Due to the high rigidity of carbon fiber materials, existing shoe soles often lack effective cushioning structures, making the feet susceptible to road vibrations and reducing riding comfort.
[0011] In existing technologies, most soles employ 0° and 90° layering methods, resulting in strong longitudinal and lateral rigidity. However, they lack optimization in diagonal directions (such as 19°, -19°, 60°, etc.), leading to uneven rigidity distribution and an inability to fully support different areas of the foot. This results in insufficient support for the metatarsophalangeal joints, affecting pedaling efficiency. The failure to provide effective support for the arch area causes foot collapse or discomfort during prolonged pedaling, increasing foot fatigue. Furthermore, the lack of targeted support design may lead to excessive stress on the metatarsal heads, causing discomfort or even injury.
[0012] Due to the high rigidity of carbon fiber, existing sole designs fail to effectively absorb vibrations during cycling, resulting in significant impact on the feet on bumpy roads and affecting the cycling experience. While using full carbon fiber filling in existing soles can provide high rigidity, the lack of a cushioning layer leads to uneven pressure on the feet, affecting comfort during long rides. Summary of the Invention
[0013] To address the aforementioned technical problems, this invention provides a carbon fiber sole structure, which is particularly suitable for use as cycling shoes, providing all-around rigidity and strength, and increasing durability.
[0014] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:
[0015] A carbon fiber sole structure includes an upper support layer, a middle support layer, a lower support layer, and a covering layer. The upper support layer, the middle support layer, and the lower support layer are sequentially stacked and connected to form the main body of the sole. The covering layer is located on the side of the main body of the sole and covers the upper support layer, the middle support layer, and the lower support layer.
[0016] As a further improvement, the lower support layer includes a lower first carbon fiber sheet, a lower second carbon fiber sheet, a lower third carbon fiber sheet, a lower fourth carbon fiber sheet, and a lower fifth carbon fiber sheet stacked sequentially from bottom to top. The lower first carbon fiber sheet and the lower second carbon fiber sheet are laid at different angles, the lower second carbon fiber sheet and the lower third carbon fiber sheet are laid at different angles, the lower third carbon fiber sheet and the lower fourth carbon fiber sheet are laid at different angles, and the lower fourth carbon fiber sheet and the lower fifth carbon fiber sheet are laid at different angles.
[0017] As a further improvement, the first carbon fiber sheet in the lower layer is laid at 0 degrees, the second carbon fiber sheet in the lower layer is laid at 19 degrees, the third carbon fiber sheet in the lower layer is laid at -19 degrees, the fourth carbon fiber sheet in the lower layer is laid at 0 degrees, and the fifth carbon fiber sheet in the lower layer is laid at 90 degrees. 0 degrees refers to the length direction of the main body of the sole, and 90 degrees refers to the width direction of the sole. The length direction and the width direction are perpendicular to each other.
[0018] As a further improvement, the middle support layer includes a first middle carbon fiber sheet, a second middle carbon fiber sheet, a third middle carbon fiber sheet, and a fourth middle carbon fiber sheet stacked sequentially. The stacked first middle carbon fiber sheet, second middle carbon fiber sheet, third middle carbon fiber sheet, and fourth middle carbon fiber sheet are rolled into a tubular carbon fiber. The tubular carbon fiber is folded into a V-shaped structure with a bottom and two side walls. The bottom of the tubular carbon fiber is located in the heel area of the main body of the sole, and the two side walls face the metatarsophalangeal joint area of the main body of the sole.
[0019] As a further improvement, the first carbon fiber sheet in the middle layer is laid at 0 degrees, the second carbon fiber in the middle layer is laid at 60 degrees, the third carbon fiber in the middle layer is laid at -60 degrees, the fourth carbon fiber in the middle layer is laid at 0 degrees, and the included angle between the two side walls of the tubular carbon fiber in the V-shaped structure is 35-40 degrees.
[0020] As a further improvement, the upper support layer includes full-length carbon yarn, half-length carbon yarn, and an arch support patch stacked sequentially from bottom to top. The area of the half-length carbon yarn is half the area of the full-length carbon yarn, and the area of the arch support patch is smaller than the area of the half-length carbon yarn.
[0021] As a further improvement, the full-length carbon yarn includes a first full-length carbon yarn layer, a second full-length carbon yarn layer, and a third full-length carbon yarn layer laid sequentially from bottom to top. The first full-length carbon yarn layer is laid at 0 degrees, the second full-length carbon yarn layer is laid at 19 degrees, and the third full-length carbon yarn layer is laid at -19 degrees.
[0022] As a further improvement, the half-palm carbon yarn includes a first half-palm carbon yarn layer and a second half-palm carbon yarn layer laid sequentially from bottom to top, with the first half-palm carbon yarn layer laid at a 45-degree angle and the second half-palm carbon yarn layer laid at a -45-degree angle.
[0023] As a further improvement, the arch support patch includes a first patch, a second patch, and a third patch arranged sequentially from bottom to top. The first patch is laid at 0 degrees, the second patch is laid at 45 degrees, and the third patch is laid at -45 degrees.
[0024] As a further improvement, a metatarsal pad made of silicone material is provided between the full-length second carbon yarn layer and the full-length third carbon yarn layer.
[0025] As a further improvement, the central support layer is filled with expanding foam.
[0026] Compared with the prior art, the present invention has the following beneficial technical effects:
[0027] 1. It adopts a multi-layer structure, with each layer using carbon fiber material stacked at multiple angles. This allows for a better rigidity distribution with less carbon fiber material, providing good rigidity support in both the lateral and longitudinal directions, thus enhancing stability.
[0028] 2. The V-shaped central support layer forms a tubular structure that conforms to the human foot arch, providing additional support, improving torsional resistance and energy transfer efficiency. It also uses foam filling to reduce the overall weight of the sole while providing cushioning to reduce vibration during riding and improve comfort.
[0029] 3. Use arch support patches to enhance arch support and reduce foot fatigue.
[0030] 4. The upper, middle and lower three-layer structure is covered with a coating layer to improve the overall torsional resistance, prevent interlayer separation, and improve durability.
[0031] By using the above-mentioned multi-layered structure, the amount of carbon fiber used is reduced, lowering the weight compared to traditional soles, while maintaining or even enhancing rigidity and torsional strength. During production, it can be molded in one piece, improving stability and durability, avoiding structural weaknesses caused by splicing, and ensuring that the sole will not deform or delaminate during riding. Attached Figure Description
[0032] Figure 1 This is a schematic cross-sectional view of the present invention.
[0033] Figure 2 This is an exploded structural diagram of the present invention.
[0034] Figure label:
[0035] Upper support layer 1, middle support layer 2, lower support layer 3, covering layer 4, full-length carbon yarn 11, half-length carbon yarn 12, arch support patch 13, full-length first carbon yarn layer 1101, full-length second carbon yarn layer 1102, full-length third carbon yarn layer 1103, first half-length carbon yarn layer 1201, second half-length carbon yarn layer 1202, first patch 1301, second patch 1302, third patch 1303, lower first carbon fiber sheet 31, lower second carbon fiber sheet 32, lower first carbon fiber sheet 33, lower fourth carbon fiber sheet 34, lower fifth carbon fiber sheet 35, metatarsal pad 5. Detailed Implementation
[0036] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.
[0037] In the description of this invention, it should be understood that if terms such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, they are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.
[0038] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection. They can refer to a mechanical connection or an electrical connection. They can refer to a direct connection or an indirect connection through an intermediate medium, and they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.
[0039] like Figure 1 and 2 As shown, a carbon fiber shoe sole structure includes an upper support layer 1, a middle support layer 2, a lower support layer 3, and a covering layer 4. The upper support layer 1, the middle support layer 2, and the lower support layer 3 are sequentially stacked and connected to form the main body of the shoe sole. The covering layer 4 is located on the side of the main body of the shoe sole and covers the upper support layer 1, the middle support layer 2, and the lower support layer 3. The covering layer 4 covers from the side, so that the upper support layer, the middle support layer, and the lower support layer are tightly connected together, improving the overall torsional resistance, preventing interlayer separation, and improving durability.
[0040] The lower support layer 3 includes a lower first carbon fiber sheet 31, a lower second carbon fiber sheet 32, a lower first carbon fiber sheet 33, a lower fourth carbon fiber sheet 34, and a lower fifth carbon fiber sheet 35, which are stacked sequentially from bottom to top. The lower first carbon fiber sheet 31 and the lower second carbon fiber sheet 32 are laid at different angles, the lower second carbon fiber sheet 32 and the lower third carbon fiber sheet 33 are laid at different angles, the lower third carbon fiber sheet 33 and the lower fourth carbon fiber sheet 34 are laid at different angles, and the lower fourth carbon fiber sheet 34 and the lower fifth carbon fiber sheet 35 are laid at different angles.
[0041] Furthermore, each sheet is laid at a specific angle. The first carbon fiber sheet at the bottom is laid at 0 degrees to provide rigidity along the long axis of the foot; the second carbon fiber sheet at the bottom is laid at 19 degrees to provide rigidity along the first metatarsophalangeal joint; the third carbon fiber sheet at the bottom is laid at -19 degrees to provide rigidity along the remaining four metatarsophalangeal joints; the fourth carbon fiber sheet at the bottom is laid at 0 degrees to provide rigidity along the long axis of the foot; and the fifth carbon fiber sheet at the bottom is laid at 90 degrees to provide lateral rigidity, thus forming the bottom support layer. This lower support layer provides the foundation for the entire shoe, becoming the base of the shoe. 0 degrees refers to the length of the sole, and 90 degrees refers to the width of the sole; the length and width directions are perpendicular to each other. If the left side of the length direction is considered a positive angle, then the right side of the length direction is a negative angle; similarly, if the right side of the length direction is considered a positive angle, then the left side of the length direction is a negative angle.
[0042] The middle support layer 2 comprises a first, second, third, and fourth carbon fiber sheet stacked sequentially. These stacked carbon fiber sheets are rolled into a tubular carbon fiber structure. This tubular carbon fiber is folded into a V-shape with a bottom and two side walls. The bottom of the tubular carbon fiber is located in the heel area of the main sole, and the side walls face the metatarsophalangeal joint area of the main sole. It can be manufactured using a yarn-rolling process.
[0043] The first carbon fiber sheet in the middle layer is laid at 0 degrees, the second carbon fiber in the middle layer is laid at 60 degrees, the third carbon fiber in the middle layer is laid at -60 degrees, the fourth carbon fiber in the middle layer is laid at 0 degrees, and the included angle between the two side walls of the tubular carbon fiber in the V-shaped structure is 35-40 degrees.
[0044] The 0-degree carbon fiber provides strong rigidity along its long axis within the tubular structure. The 60-degree and -60-degree carbon fibers function to enclose the 0-degree carbon fibers within the tubular structure. When the 0-degree carbon fiber is subjected to pressure in its normal direction, it tends to break outwards; at this point, the 60-degree and -60-degree carbon fibers act to hold the 0-degree carbon fiber within. The two side walls of the V-shape point towards the metatarsophalangeal joint of the big toe and the metatarsophalangeal joints of the other four fingers, with an opening size of approximately 38 degrees. Human anatomy is divided into the medial arch, lateral arch, and transverse arch. When cycling, power originates from the thigh, and the force generated by the thigh acts vertically downwards on the subtalar joint. This force is ultimately supported by the longitudinal arches on both sides of the foot in the cycling shoe. The V-shaped structure effectively supports the medial and lateral arches, greatly improving the shoe's rigidity and strength. This design conforms to ergonomic principles and human anatomy.
[0045] In addition, expanding foam can be incorporated into the midsole support layer. The purpose of the expanding foam is to fill the gaps, reducing the overall weight of the shoe. Furthermore, compared to cycling shoes entirely filled with carbon fiber, using expanding foam provides excellent cushioning. When used as a cycling shoe, it prevents excessive shock to the arch and foot when encountering uneven surfaces, thanks to the cushioning effect of the expanding foam.
[0046] The upper support layer 1 includes a full-length carbon yarn 11, a half-length carbon yarn 12, and an arch support patch 13 stacked sequentially from bottom to top. The area of the half-length carbon yarn 12 is half the area of the full-length carbon yarn 11, and the area of the arch support patch 13 is smaller than the area of the half-length carbon yarn 12. The full-length carbon yarn 11 includes a first full-length carbon yarn layer 1101, a second full-length carbon yarn layer 1102, and a third full-length carbon yarn layer 1103 laid sequentially from bottom to top. The first full-length carbon yarn layer is laid at 0 degrees, the second full-length carbon yarn layer at 19 degrees, and the third full-length carbon yarn layer at -19 degrees.
[0047] The full-length first carbon yarn layer provides long-axis stiffness to the foot. The full-length second and third carbon yarn layers are laid at 19 degrees and -19 degrees, respectively, to provide phalangeal support in the direction of the big toe and the other four toes.
[0048] The half-palm carbon yarn 12 includes a first half-palm carbon yarn layer 1201 and a second half-palm carbon yarn layer 1202 laid sequentially from bottom to top. The first half-palm carbon yarn layer is laid at a 45-degree angle, and the second half-palm carbon yarn layer is laid at a -45-degree angle.
[0049] The half-length carbon fiber provides support for the midfoot. When cycling, the midfoot and forefoot, as well as the midfoot and rearfoot, undergo varying degrees of torsion, with an angle of approximately 10 degrees or less. Such torsion can increase foot fatigue and reduce athletic performance. Reduced movement of small joints during cycling decreases energy expenditure in small muscle groups, reducing the risk of injury. Therefore, the midfoot support layer primarily serves to protect the arch of the foot.
[0050] A silicone metatarsal pad 5 is provided between the full-length second carbon yarn layer 1102 and the full-length third carbon yarn layer 1103. The metatarsal pad 5 is teardrop-shaped and positioned behind the head of the second metatarsal. The function of the metatarsal pad is to support the second metatarsal, which tends to sink in most people, preventing the metatarsal head from excessively contacting the ground. Made of soft silicone, the pad provides excellent comfort for the foot. The silicone and carbon fiber are molded together in one piece, creating different levels of softness on the contact surface between the foot and the bicycle shoe, improving comfort while maintaining the functionality of the bicycle shoe and correcting the arch of the foot.
[0051] The arch support patch 13 includes a first patch 1301, a second patch 1302, and a third patch 1303 arranged sequentially from bottom to top. The first patch is laid at 0 degrees, the second patch at 45 degrees, and the third patch at -45 degrees. The arch support patch is the inner support piece located in the semi-length support layer. Its main function is to elevate the inner part to a certain extent, conforming to the anatomical structure of the human inner arch. The inner foot of the human body has a transverse, elastic arch, which straightens when force is transmitted downwards. Repeated straightening and rebound can cause significant fatigue for cyclists. By using the inner arch patch to elevate the inner arch, cyclists can enjoy greater comfort while riding.
[0052] The overlay uses two strips of 0-degree carbon yarn for wrapping, specifically wrapping the upper, middle, and lower support layers around their perimeter. The purpose is to tightly bond the three support layers together. Unlike carbon fiber bicycle shoes with a simple stacked structure, this perimeter wrapping provides the shoe with a degree of torsional resistance. Because the structure of the human foot dictates that the forefoot, midfoot, and hindfoot rotate relative to each other around the foot's long axis, a simple stacked structure for the entire bicycle shoe would risk separation between the layers. Using strips of carbon yarn to wrap the perimeter of the bicycle shoe significantly stabilizes the overall structure, enabling it to largely resist the torsion of the foot during cycling.
[0053] It should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. However, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A carbon fiber sole structure, characterized by, The upper support layer, the middle support layer, the lower support layer and the cladding layer are sequentially stacked and connected to form a shoe sole main body, and the cladding layer is arranged on the side of the shoe sole main body and covers the upper support layer, the middle support layer and the lower support layer.
2. The carbon fiber sole structure of claim 1, wherein, The lower support layer comprises a lower first carbon fiber sheet, a lower second carbon fiber sheet, a lower third carbon fiber sheet, a lower fourth carbon fiber sheet and a lower fifth carbon fiber sheet arranged in sequence from bottom to top, the laying angles of the lower first carbon fiber sheet and the lower second carbon fiber sheet are different, the laying angles of the lower second carbon fiber sheet and the lower third carbon fiber sheet are different, the laying angles of the lower third carbon fiber sheet and the lower fourth carbon fiber sheet are different, and the laying angles of the lower fourth carbon fiber sheet and the lower fifth carbon fiber sheet are different.
3. The carbon fiber sole structure of claim 2, wherein, The first carbon fiber sheet is laid at 0 degrees, the second carbon fiber sheet is laid at 19 degrees, the third carbon fiber sheet is laid at -19 degrees, the fourth carbon fiber sheet is laid at 0 degrees, and the fifth carbon fiber sheet is laid at 90 degrees, 0 degrees refers to the length direction of the shoe sole main body, and 90 degrees refers to the width direction of the shoe sole.
4. The carbon fiber sole structure of claim 3, wherein, The middle support layer comprises a middle first carbon fiber sheet, a middle second carbon fiber sheet, a middle third carbon fiber sheet and a middle fourth carbon fiber sheet arranged in sequence, the middle first carbon fiber sheet, the middle second carbon fiber sheet, the middle third carbon fiber sheet and the middle fourth carbon fiber sheet are rolled into a tubular carbon fiber, the tubular carbon fiber is folded into a V-shaped structure with a bottom and two side walls, the bottom of the tubular carbon fiber is located in the heel area of the shoe sole main body, and the two side walls are directed to the metatarsophalangeal joint area of the shoe sole main body.
5. The carbon fiber sole structure of claim 4, wherein, The first carbon fiber sheet is laid at 0 degrees, the second carbon fiber sheet is laid at 60 degrees, the third carbon fiber sheet is laid at -60 degrees, the fourth carbon fiber sheet is laid at 0 degrees, and the included angle between the two side walls in the tubular carbon fiber of the V-shaped structure is 35-40 degrees.
6. The carbon fiber sole structure of claim 5, wherein, The upper support layer comprises a full-palm carbon yarn, a half-palm carbon yarn and an arch support patch arranged in sequence from bottom to top, the area of the half-palm carbon yarn is half of the area of the full-palm carbon yarn, and the area of the arch support patch is smaller than the area of the half-palm carbon yarn.
7. The carbon fiber sole structure of claim 6, wherein, The full-palm carbon yarn comprises a full-palm first carbon yarn layer, a full-palm second carbon yarn layer and a full-palm third carbon yarn layer laid in sequence from bottom to top, the full-palm first carbon yarn layer is laid at 0 degrees, the full-palm second carbon yarn layer is laid at 19 degrees, and the full-palm third carbon yarn layer is laid at -19 degrees, and a metatarsal pad made of silica gel is arranged between the full-palm second carbon yarn layer and the full-palm third carbon yarn layer.
8. The carbon fiber sole structure of claim 7, wherein, The half-palm carbon yarn comprises a first half-palm carbon yarn layer and a second half-palm carbon yarn layer laid in sequence from bottom to top, the first half-palm carbon yarn layer is laid at 45 degrees, and the second half-palm carbon yarn layer is laid at -45 degrees.
9. The carbon fiber sole structure of claim 8, wherein, The arch support patch comprises a first patch, a second patch and a third patch arranged in sequence from bottom to top, the first patch is laid at 0 degrees, the second patch is laid at 45 degrees, and the third patch is laid at -45 degrees.
10. The carbon fiber sole structure of claim 9, wherein, The middle support layer is filled with foaming glue.