Recycled Carbon Fiber Arch Insole

Abstract

To provide a recycled carbon fiber arch insole with a recycled carbon fiber pad, and a method for manufacturing a recycled carbon fiber pad.SOLUTION: A method for manufacturing a recycled carbon fiber pad includes mixing recycled carbon fiber materials with nylon or composite plastic and forming an elastic recycled carbon fiber injection particle materials, to inject the recycled carbon fiber injection particle materials under an injection process condition and mold into a recycled carbon fiber pad.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to the technical field of arch insoles for shoes, and in particular to recycled carbon fiber arch insoles having recycled carbon fiber pads. The present invention also relates to a manufacturing method for the recycled carbon fiber pads. [Background technology]

[0002] People generally put arch insoles in their shoes to reduce stress and vibration when walking or running, improving comfort. Especially in the post-COVID era, health is given special importance, and the demand for insoles with mechanical arch function in medical and health care fields is increasing day by day.

[0003] Traditional arch insoles are mainly made of pure carbon fiber, plastics such as PP, PE, TPU, and petrochemical plastic materials such as resin carbon fiber composites, which are relatively difficult to manufacture and have poor elasticity (e.g., too hard, too thick), resulting in poor functionality.

[0004] Furthermore, although carbon fiber materials are widely used in shoes and other applications, they still have the problem that the materials are too hard and inelastic. None of the above materials can be recycled, and they are prone to environmental pollution and waste that will remain for a hundred years, so it is necessary to recover the waste through the gradually matured carbon fiber material recovery technology and develop and apply it, so as to improve the problem and create a recycling eco-product circulation, thereby achieving the goal of reducing the carbon emissions of the manufacturing process and products.

[0005] In addition, there are currently many types of arch insoles on the market, and most of them that are said to have medical effects are not actually ergonomic or medical mechanics designed, and do not have actual medical certification. At the same time, existing arch insoles usually lack medial arch support and have design errors in the support shape of the lateral arch pads, which leads consumers to waste money or be deceived after trying them out. Summary of the Invention [Problem to be solved by the invention]

[0006] In order to solve the various problems of the traditional arch insole, the present invention provides a method for manufacturing a recycled carbon fiber pad, and proposes a recycled carbon fiber arch insole including the recycled carbon fiber pad manufactured by the method. Currently, the recycling manufacturing process is calculated to generate and emit 4 to 4.5 tons of CO2 per ton of recycled carbon fiber RCF, and the current carbon fiber manufacturing process in the industry generates 20 tons of CO2 per ton of carbon fiber CF, so the use of recycled carbon fiber material can effectively reduce carbon emissions by nearly 80%. [Means for solving the problem]

[0007] The method for producing the recycled carbon fiber pad includes the steps of providing a recycled carbon fiber material, and TPU Providing a composite plastic; The TPU It is mixed with composite plastic and has elasticity. injection material and forming said injection material and injection molding the recycled carbon fiber material into a recycled carbon fiber pad, the recycled carbon fiber material having a first content percentage and a first weight percentage, the nylon or The TPUThe composite plastic has a second content percentage and a second weight percentage, the sum of the second content percentage and the first content percentage is one hundred percent, the sum of the second weight percentage and the first weight percentage is one hundred percent, and the injection process conditions include at least one of a default mold temperature, a default cooling time, a default screw rotation speed, a default injection time, and a default in-mold zone temperature.

[0008] In a non-limiting embodiment, the first content percentage is between 10% and 30% and the second content percentage is between 70% and 90%.

[0009] In a non-limiting embodiment, the first weight percentage is 50% and the second weight percentage is 50%.

[0010] In a non-limiting embodiment, the recycled carbon fiber material is short fiber powder of 0.1 mm to 0.5 mm.

[0011] In a non-limiting embodiment, nylon is either PA6 level nylon or PA12 level nylon.

[0012] In a non-limiting embodiment, the default mold temperature is 70°C.

[0013] In a non-limiting embodiment, the default cooling time is 15 seconds.

[0014] In a non-limiting embodiment, the default screw rotation speed is 88 rpm.

[0015] In a non-limiting embodiment, the default firing time is 1.5 seconds.

[0016] In a non-limiting embodiment, the default in-mold zone temperatures are a first zone temperature of 260°C to a fifth zone temperature of 225°C.

[0017] The recycled carbon fiber arch insole includes a recycled carbon fiber pad, and the recycled carbon fiber pad is manufactured by the manufacturing method for the recycled carbon fiber pad.

[0018] In a non-limiting embodiment, the recycled carbon fiber arch insole further includes a first cushioning layer overlying the recycled carbon fiber pad.

[0019] In a non-limiting embodiment, the first cushioning layer is defined by a total foot length and the length of the recycled carbon fiber pad is three-quarters of the total foot length.

[0020] In a non-limiting embodiment, the recycled carbon fiber arch insole further includes a graphene pad overlying the first cushioning layer.

[0021] In a non-limiting embodiment, the length of the graphene pad is equal to the total foot length.

[0022] In a non-limiting embodiment, the graphene pad is made of a knitted fabric that is a mixture of 92% graphene yarn and 8% elastic yarn.

[0023] In a non-limiting embodiment, the surface of the graphene pad is further printed with honeycomb graphene material.

[0024] In a non-limiting embodiment, the recycled carbon fiber arch insole further includes at least one second cushioning layer sandwiched between the recycled carbon fiber pad and the first cushioning layer.

[0025] In a non-limiting embodiment, the first cushion layer is a foam material and the at least one second cushion layer is a rubber sheet.

[0026] In a non-limiting embodiment, the recycled carbon fiber pad has a particular contour, and the particular contour is determined by a plurality of corresponding contour statistics in a database.

[0027] In a non-limiting embodiment, the plurality of corresponding contour statistics include a contour statistic corresponding to a foot midline length, a contour statistic corresponding to an inner foot length, a contour statistic corresponding to a outer foot length, a contour statistic corresponding to a foot toe width, a contour statistic corresponding to an arch width, a contour statistic corresponding to a heel width, a contour statistic corresponding to an inner foot arch height, a contour statistic corresponding to an inner foot arch position, a contour statistic corresponding to an outer foot arch height, and a contour statistic corresponding to an outer foot arch position.

[0028] In a non-limiting embodiment, the particular contour comprises an arch height and a width, the arch height including a low arch height, a standard arch height, and a high arch height, and the width including a narrow width, a standard width, and a wide width.

[0029] As described above, by using recycled carbon fiber materials instead of traditional plastic materials to manufacture recycled carbon fiber pads and recycled carbon fiber arch insoles including recycled carbon fiber pads, the effect of recycling and reusing can be effectively achieved to meet environmental needs, and the usability of the recycled carbon fiber arch insoles can be improved due to the properties of the recycled carbon fiber materials themselves, such as light weight, high elasticity, fatigue resistance, ease of manufacture, high strength and toughness, and resistance to deformation.

[0030] The contour of the recycled carbon fiber pad can be designed and sized based on various foot shape conditions using big data to meet different needs. This allows customization, improving the versatility of use. Furthermore, the health function of far-infrared rays from graphene material can be used to provide the recycled carbon fiber arch insole with health benefits. [Brief description of the drawings]

[0031] [Figure 1] FIG. 1 is an exploded perspective view of a recycled carbon fiber arch insole according to a preferred embodiment of the present invention. [Diagram 2]FIG. 2 is a process diagram of a method for producing a recycled carbon fiber pad according to a preferred embodiment of the present invention. [Diagram 3] FIG. 2 is a sample schematic diagram of a foot shape definition according to a preferred embodiment of the present invention. [Figure 4] FIG. 13 is another sample schematic diagram of a foot shape definition according to a preferred embodiment of the present invention. [Diagram 5] FIG. 2 is a schematic diagram showing the contour change of a recycled carbon fiber pad according to a preferred embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] In order to fully understand the objects, features and advantages of the present invention, preferred embodiments of the present invention will be described with reference to the accompanying drawings.

[0033] Please refer to Fig. 1. Fig. 1 is an exploded perspective view of a recycled carbon fiber arch insole according to a preferred embodiment of the present invention. Fig. 1 shows a recycled carbon fiber arch insole 1 that can be installed in a shoe (not shown), and the recycled carbon fiber arch insole 1 mainly includes a recycled carbon fiber pad 11 and a first cushion layer 12, and as shown in Fig. 1, in this embodiment, the recycled carbon fiber arch insole 1 further includes a graphene pad 13 and two second cushion layers 14, the first cushion layer 12 is superimposed on the recycled carbon fiber pad 11, the graphene pad 13 is superimposed on the first cushion layer 12, and the two second cushion layers 14 are sandwiched between the recycled carbon fiber pad 11 and the first cushion layer 12, respectively.

[0034] The first cushioning layer 12 is a foam material, and the two second cushioning layers 14 are rubber sheets, which can be used to reduce stress and vibration, and improve the comfort of people using the recycled carbon fiber arch insole 1. Of course, the first cushioning layer 12 and the second cushioning layer 14 can be designed inversely.

[0035] That is, the first cushion layer 12 may be a rubber sheet, and the second cushion layer 14 may be a foam material. The number of the second cushion layers 14 is not limited to two as shown in Fig. 1, but may be one, three or other numbers, and the shape, length, width, height, installation position, etc. may be changed according to actual needs. For example, different designs may be made according to different arch heights, foot widths, foot lengths, etc.

[0036] In this embodiment, the graphene pad 13 (which may be called graphene surface cloth) is made of a knitted fabric that is a mixture of 92% graphene yarn and 8% elastic yarn, and the surface of the graphene pad 13 is printed with a honeycomb graphene material 131. In this way, the graphene content can be further increased. Graphene has health benefits such as promoting blood circulation in the soles of the feet and increasing blood flow rate.

[0037] According to the certification test by a notary public, the graphene pad 13 designed by the above method has a far-infrared emissivity of 0.83 or more. When the recycled carbon fiber arch insole is used for one hour, the temperature rise test of the hands and feet can be improved by 13°C, the blood flow rate can be improved by +11%, the blood oxygen concentration in the fingertips can be improved by +1.0, and the skin temperature can be improved by +9°C.

[0038] In addition, as mentioned above, the recycled carbon fiber arch insole 1 includes a recycled carbon fiber pad 11, i.e., the pad is made of recycled carbon fiber material instead of traditional plastic material, which can effectively achieve the effect of recycling and meeting environmental needs.

[0039] In addition, the recycled carbon fiber material itself has many properties, such as light weight, thinness, high elasticity, fatigue resistance, ease of manufacture, high strength and toughness, and resistance to deformation, so by manufacturing a pad from the recycled carbon fiber material and using the pad in the recycled carbon fiber arch insole 1, it is possible to increase the usability of the recycled carbon fiber arch insole 1. A method for manufacturing the recycled carbon fiber pad 11 will be described below.

[0040] Please refer to Fig. 2. Fig. 2 is a process diagram of a method for manufacturing a recycled carbon fiber pad according to a preferred embodiment of the present invention, which shows steps of the method for manufacturing a recycled carbon fiber pad 11 included in a recycled carbon fiber arch insole 1. Please also refer to Fig. 1.

[0041] In the steps of the method for producing the recycled carbon fiber pad 11, a recycled carbon fiber material is first provided. The recycled carbon fiber material has a first content percentage and a first weight percentage (step S01). In this embodiment, the first content percentage of the recycled carbon fiber material is 10% to 30%, for example, 10%, 15%, 20%, 25%, 30%, etc., and the first weight percentage is 50%.

[0042] Next, nylon or TPU Provide a composite plastic. This nylon or TPU The composite plastic has a second content percentage and a second weight percentage and is made of nylon or TPU The sum of the second content percentage of the composite plastic and the first content percentage of the recycled carbon fiber material is 100%, and the nylon or TPU The sum of the second weight percentage of the composite plastic and the first weight percentage of the recycled carbon fiber material is 100% (step S02). TPU The second content percentage of the composite plastic is between 70% and 90% and the second weight percentage is 50%.

[0043] A first content percentage of the recycled carbon fiber material and nylon or TPU Regarding the second content percentage of the composite plastic, for example, when the first content percentage is 10%, the second content percentage is 90%, when the first content percentage is 15%, the second content percentage is 85%, when the first content percentage is 20%, the second content percentage is 80%, when the first content percentage is 25%, the second content percentage is 75%, when the first content percentage is 30%, the second content percentage is 70%, etc.

[0044] Of course, if the first content percentage is 12%, the second content percentage may be 88%, if the first content percentage is 13%, the second content percentage may be 87%, if the first content percentage is 16%, the second content percentage may be 84%, if the first content percentage is 18%, the second content percentage may be 82%, etc., and may be changed according to actual production needs.

[0045] Then, recycled carbon fiber material nylon Mixing with injection material Form Or, recycled carbon fiber material is mixed with TPU composite plastic to form the injection material. (Step S03). This is called the mixing process.

[0046] And depending on the injection process conditions, injection material is injection molded into the recycled carbon fiber pad 11, and the injection process conditions include at least one of a default mold temperature, a default cooling time, a default screw rotation speed, a default injection time, and a default in-mold zone temperature (step S04).

[0047] In step S04, the various parameters included in the injection process conditions include the ratio of the first content percentage and the first weight percentage of the recycled carbon fiber material, and the ratio of the nylon or TPU At least one of them may be set based on a ratio of a corresponding second content percentage and a second weight percentage of the compounded plastic.

[0048] For example, the first content percentage of the recycled carbon fiber material is 15%, the first weight percentage is 50%, and the nylon or TPU When the corresponding second content percentage of the composite plastic is 85% and the second weight percentage is 50%, the injection process conditions include a default mold temperature of 70°C, a default cooling time of 15 seconds, a default screw rotation speed of 88 rpm, a default injection time of 1.5 seconds, and a default in-mold zone temperature ranging from a first zone temperature of 260°C to a fifth zone temperature of 225°C.

[0049] By individually adjusting the settings of various parameters included in the injection process conditions, recycled carbon fiber pads 11 required under different content ratio and weight ratio conditions can be produced, for example, recycled carbon fiber pads 11 having a tensile strength of 125±10 MPa, a flexural strength of 192±10 MPa, and a flexural modulus of 6.6±2 GPa can be obtained.

[0050] The recycled carbon fiber material may be short fiber powder having a size of 0.1 mm to 0.5 mm, such as 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, and nylon can be either PA6 level nylon or PA12 level nylon, and of course other composite plastics can be used. Similarly, the various parameters included in the injection process conditions are determined by the recycled carbon fiber material and nylon or TPU At least one of them may be set based on different types of composite plastics, so that, for example, a recycled carbon fiber pad 11 that satisfies the various test conditions described above can be obtained.

[0051] Please refer to Fig. 1 again. As described above, the recycled carbon fiber arch insole 1 includes a recycled carbon fiber pad 11, a second cushion layer 14, a first cushion layer 12 and a graphene pad 13, which are overlapped with each other, and the first cushion layer 12 is defined by the total foot length, that is, the length of the entire foot plate from the heel to the tip of the toes, and the length of the graphene pad 13 is equal to the total foot length, that is, the graphene pad 13 and the first cushion layer 12 have the same length. As can be seen from Fig. 1, the graphene pad 13 and the first cushion layer 12 have the same outer contour. Of course, the graphene pad 13 and the first cushion layer 12 may be designed to have different lengths and different outer contours.

[0052] The length of the recycled carbon fiber pad 11 is three-quarters of the total foot length, and includes the range of the calcaneus (rear foot) and metatarsus (midfoot), that is, a three-quarter arch insole framework design. In detail, the recycled carbon fiber pad 11 has a specific contour, and this specific contour is determined by a plurality of corresponding contour statistics in a database, and the database is a database of human foot shapes, which may be, for example, customer foot shape data accumulated by general traders through years of sales of related arch insole products, or may be digital data of subjects' foot shapes accumulated by related medical research institutions through research on various foot shapes (for example, foot shapes with three different arch heights: low, standard, and high), and the database may be further classified into digital data of foot shapes by race.

[0053] For example, the specific contour of the recycled carbon fiber pad 11 may be determined by the foot shapes of 37,500 Asian adults, a (big) database obtained by a manufacturer through years of selling arch insole products.

[0054] Please refer to Fig. 3 and Fig. 4 at the same time. Fig. 3 is one sample schematic diagram of a foot type definition according to a preferred embodiment of the present invention, and Fig. 4 is another sample schematic diagram of a foot type definition according to a preferred embodiment of the present invention, and Fig. 3 and Fig. 4 are only used for reference and are used to illustrate the definition of foot type in this field.

[0055] Please refer to Figures 3 and 4. The plurality of corresponding contour statistics include a contour statistics corresponding to a foot midline length, a contour statistics corresponding to a foot medial length, a contour statistics corresponding to a foot lateral length, a contour statistics corresponding to a foot toe width, a contour statistics corresponding to a foot arch width, a contour statistics corresponding to a foot heel width, a contour statistics corresponding to a foot medial arch height, a contour statistics corresponding to a foot medial arch position, a contour statistics corresponding to a foot lateral arch height, and a contour statistics corresponding to a foot lateral arch position.

[0056] Therefore, the specific contour of the three-quarter arch insole framework design of the recycled carbon fiber pad 11 can be designed and obtained based on the statistics of the big data (i.e., so-called ergonomics), and thus the manufactured recycled carbon fiber pad 11 conforms to human biomechanics.

[0057] Please refer to Figure 5. Figure 5 is a schematic diagram of the contour change of the recycled carbon fiber pad according to a preferred embodiment of the present invention. As mentioned above, the specific contour of the recycled carbon fiber pad 11 can be designed and made into many different sizes based on different foot shape conditions using big data, for example, the specific contour can have different arch heights and widths to meet different needs.

[0058] Therefore, customization (e.g., use for daily activities, use for strenuous exercise, use for corrective support, etc.) can be performed, thereby improving the versatility of use.

[0059] For example, as shown in Fig. 5, according to low, standard and high arch heights (i.e. low arch height, standard arch height and high arch height) displayed from left to right, and each arch height design has narrow, standard and wide sizes (i.e. narrow width, standard width and wide width) to meet many application needs in current shoe types, the specific contour of the three-quarter arch insole framework design of the recycled carbon fiber pad 11 can be changed in design for the different situations according to the big data. In this way, many different sizes can be obtained to meet different needs.

[0060] Although the present invention has been described above with reference to preferred embodiments, the above embodiments are merely used to explain the present invention for those skilled in the art and should not be construed as limiting the scope of the present invention. It should be noted that any equivalent modifications or replacements of the above embodiments are also within the scope of the present invention. Therefore, the scope of protection of the present invention is subject to that defined in the claims. [Explanation of symbols]

[0061] 1 Recycled Carbon Fiber Arch Insole 11 Recycled Carbon Fiber Pad 12 First cushion layer 13 Graphene Pad 131 Honeycomb graphene material 14 Second cushion layer S01 Step S02 Step S03 Step S04 Step

Claims

1. A recycled carbon fiber pad formed by mixing recycled carbon fiber material with nylon to form a particle-ejected material of elastic recycled carbon fiber, and extrusion molding the particle-ejected material under injection process conditions, wherein the recycled carbon fiber material has a first content percentage and a first weight percentage, the nylon has a second content percentage and a second weight percentage, the sum of the second content percentage and the first content percentage is one hundredth of a percent, and the sum of the second weight percentage and the first weight percentage is one hundredth of a percent; A first cushion layer overlaid on the recycled carbon fiber pad; A graphene pad is superimposed on the first cushion layer and has a honeycomb graphene material printed on a surface thereof. Recycled carbon fiber arch insole.

2. The first cushioning layer is defined by a total foot length, and the length of the recycled carbon fiber pad is three-quarters of the total foot length.

10. The recycled carbon fiber arch insole of claim 1.

3. Further comprising at least one second cushion layer sandwiched between the recycled carbon fiber pad and the first cushion layer.

10. The recycled carbon fiber arch insole of claim 1.

4. The recycled carbon fiber pad has a specific contour; and the particular contour is determined by a plurality of corresponding contour statistics in a database; The plurality of corresponding contour statistics include a contour statistic corresponding to a foot midline length, a contour statistic corresponding to a foot medial length, a contour statistic corresponding to a foot lateral length, a contour statistic corresponding to a foot toe width, a contour statistic corresponding to a foot arch width, a contour statistic corresponding to a foot heel width, a contour statistic corresponding to a foot medial arch height, a contour statistic corresponding to a foot medial arch position, a contour statistic corresponding to a foot lateral arch height, and a contour statistic corresponding to a foot lateral arch position.

10. The recycled carbon fiber arch insole of claim 1.

5. The particular profile has an arch height and a width, the arch height including a low arch height, a standard arch height, and a high arch height; The widths include narrow widths, standard widths and wide widths.

5. The recycled carbon fiber arch insole of claim 4.

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