Supporting structures for shoe soles and manufacturing method thereof

Abstract

The support structure applied to the sole of a shoe, including the forefoot, midfoot, and heel areas, comprises multiple fiber rods and intersecting sections. Each fiber rod extends within the sole and includes a polymer matrix and multiple filaments dispersed within the polymer matrix and extending along the direction of the fiber rod. At least two fiber rods are connected and joined together in the heel area. Each intersecting section is formed by the intersection of any two fiber rods and is an integrally molded pattern. The intersecting section defines four sets of adjacent complementary angles, each set having a common edge and a non-common edge. The intersecting section includes filaments in a continuous pattern extending from the common edge to the non-common edge. The number of intersecting sections in the midfoot area is greater than the number of intersecting sections in the forefoot area, and the density of filaments in each fiber rod is substantially the same as the density of filaments in the intersecting sections.

Claims

1. A support structure for use in a shoe sole, the shoe sole including a forefoot area, a midfoot area, and a heel area, the support structure comprising: A plurality of fiber rods extend in the sole, each of the fiber rods comprising a polymer matrix and a plurality of fiber filaments dispersed in the polymer matrix and extending along the direction of the fiber rods, and at least two ends of each of the fiber rods being connected and joined together in the heel area of ​​the sole; and an intersection formed by the intersection of any two of the fiber rods and being integrally molded, the intersection defining four sets of adjacent complementary angles, each of the adjacent complementary angles having a common side and a non-common side, and the intersection comprising the fiber filaments in a continuous pattern extending from the common side to the non-common side; wherein the number of the intersections located in the midfoot area is greater than the number of the intersections located in the forefoot area, and the density of the fiber filaments in each of the fiber rods is substantially the same as the density of the fiber filaments located in the intersection.

2. The support structure as claimed in claim 1, wherein the absolute value of the error between the density of the fibers in each of the fiber rods and the density of the fibers located at the intersection is less than or equal to 5%.

3. The support structure as claimed in claim 1, wherein the intersection comprises filaments in a continuous pattern that folds back from the common side or the non-common side and does not pass through a center point of the intersection.

4. The support structure as claimed in claim 1, wherein the fiber rods located in the front foot area are spaced apart from each other and do not intersect.

5. The support structure as claimed in claim 1, wherein the support structure has substantially the same thickness in the forefoot area, the midfoot area and the heel area.

6. A method for manufacturing a support structure for use in a shoe sole, the shoe sole comprising a forefoot area, a midfoot area, and a heel area, the method comprising: Position a substrate layer, the surface of which has a pre-defined pattern for constructing the support structure; According to the preset pattern, a fiber bundle is laid along a preset path; a wire is sewn along the laying of the fiber bundle to fix the fiber bundle to the substrate layer; and the fiber bundle and the wire are melted and cooled to form a support structure consisting of a plurality of fiber rods corresponding to the preset pattern, wherein each of the fiber rods includes a polymer matrix and a plurality of fiber filaments dispersed in the polymer matrix and extending along the direction of the fiber rod, and at least two of the fiber rods are connected and joined together in the heel area of ​​the sole; wherein the support structure includes at least one intersection formed by the intersection of any two of the fiber rods, and the intersection defines four sets of adjacent corners, each of the adjacent corners having a common side and a non-common side, wherein the intersection includes the fiber filaments in a continuous pattern extending from the common side to the non-common side; The number of the cross sections in the midfoot area of ​​the support structure is greater than the number of the cross sections in the forefoot area, and the density of the fibers in each of the fiber rods is substantially the same as the density of the fibers in the cross sections.

7. A method for manufacturing a support structure as described in claim 6, wherein laying the fiber bundle along the predetermined path comprises: For each of the intersections, a fiber bundle of the continuous pattern extending from the common side to the non-common side is laid out for any of the adjacent corners.

8. A method for manufacturing a support structure as described in claim 6, wherein laying the fiber bundle along the predetermined path comprises: For each of the intersections, a continuous fiber bundle extending along the non-common edge and passing through a center point of the intersection is laid out for any of the adjacent corners.

9. A method for manufacturing a support structure as described in claim 6, wherein laying the fiber bundle along the predetermined path comprises: For each of the intersections, a fiber bundle is laid out in a continuous pattern extending along the common edge or the non-common edge, turning back at the common edge or the non-common edge, and not passing through a center point of the intersection, for any of the adjacent corners.

10. A method for manufacturing a support structure as claimed in claim 6, wherein the fiber bundle comprises a plurality of fibers, and the fibers comprise a polymer material and an inorganic material, wherein the polymer material is melted and cooled to form the polymer matrix, and the inorganic material forms the fiber filaments.

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