Reinforced structure for footwear

Abstract

A reinforced structure for footwear includes a rod and a reinforcing structure. At least a portion of the rod protrudes toward or away from a horizontal plane in a curved manner. When the rod is subjected to a pressure from the horizontal plane, the curvature of the rod decreases, and the rod deforms in an elongating manner along a longitudinal direction. The reinforcing structure is joined to at least a portion of the rod via a connecting part, thereby providing the reinforced structure for footwear with high stability and enhanced adaptability through a balanced combination of rigidity and flexibility.

Description

FIELD OF INVENTION

[0001] The present invention relates to a reinforced structure, and more particularly to a reinforced structure for footwear.BACKGROUND OF THE INVENTION

[0002] In conventional footwear technology, in order to enhance the elasticity and support of shoe soles, foamed materials are commonly manufactured from raw materials such as ethylene-vinyl acetate (EVA) copolymers or polyurethane (PU). Structural designs including bumpy patterns, holes, air bags, pads, or support columns are employed to absorb impact and improve wearing comfort. However, structures made from such materials are generally homogeneous and lack anisotropic strength differences. As a result, enhancing elasticity often requires sacrificing support, while enhancing support leads to insufficient elasticity, thereby limiting further optimization of footwear performance.

[0003] In order to reinforce the sole structure, some designs also introduce composite materials such as carbon fibers or glass fibers to increase overall strength and durability. Although such materials have advantages in providing strength and weight reduction, they may still perform inadequately under high impact or extreme usage conditions. In addition, due to their high rigidity, they are likely to reduce the overall flexibility of the sole. Furthermore, if the interface treatment between the reinforcing material and the matrix material is improper, failure issues such as stress concentration or interfacial delamination may occur, further weakening the structural performance.

[0004] In recent years, with the growing public awareness of sports, the performance requirements for footwear in different athletic scenarios have become increasingly diverse. In addition to providing high-strength support, the sole must also ensure flexibility and comfort. Although materials such as carbon fibers can enhance plantar support strength, their rigidity may cause discomfort in sports that require frequent changes of direction or high flexibility, and may even lead to fatigue and injury after prolonged wear, thereby adversely affecting overall athletic performance. Accordingly, achieving a balance between strength and flexibility remains an important challenge in current footwear design.

[0005] Therefore, it is an objective in the related art to develop a reinforced structure for footwear that provides high stability and improves adaptability by balancing rigidity and flexibility.SUMMARY OF THE INVENTION

[0006] To develop a reinforced structure for footwear with high stability that can enhance adaptability by balancing rigidity and flexibility, the present invention provides a reinforced structure for footwear, comprising: at least one rod, wherein at least a portion of the rod is curved either toward or away from a horizontal plane, and when the rod receives a pressure from the horizontal plane, the bending amplitude of the rod is reduced and the rod deforms in a longitudinal direction; and a reinforcing structure, coupled to at least a portion of the rod via a coupling part.

[0007] Wherein, an angle is formed between any two segments of the rod, a gap is formed between any two segments of the rod, the two ends of the rod correspond to respective ends in the longitudinal direction, and an opening is formed between the two ends.

[0008] Wherein, multiple of the rods are arranged with spacing or in an interleaved manner, a gap is formed between at least two of the rods, each rod having an axis defining the longitudinal direction, two adjacent rods defining a width direction perpendicular to the longitudinal direction, at least a portion of at least two of the rods being formed in a common plane, and at least a portion of the longitudinal direction of two adjacent rods forming a height difference.

[0009] Wherein, the reinforcing structure is continuously disposed in the width direction between the rods, so that when the rods receive pressure from the horizontal plane, the reinforcing structures and the rods extend in the width direction.

[0010] Wherein, at least two of the rods are bent in different bending directions or have different bending curvatures relative to the horizontal plane, wherein multiple of the rods are arranged in an interlaced or intertwined manner to form a mesh-like structure, and wherein at least a portion of the rods collectively form a curved surface.

[0011] Wherein, at least a portion of the reinforcing structure is disposed in the gap, and the reinforcing structure is coplanar with the gap.

[0012] Wherein, at least a portion of the reinforcing structure is disposed in the gap, and the rod protrudes relative to the bending direction.

[0013] Wherein, both the rod and the reinforcing structure are concavely curved toward the bending direction, and the bending amplitude of the reinforcing structure is smaller than the bending amplitude of the rod.

[0014] Wherein, the reinforcing structure extends along the longitudinal direction of the rod, and the two coupling parts are connected to the rod at both ends in the longitudinal direction.

[0015] Wherein, the reinforcing structure is disposed between two adjacent rods, and the reinforcing structure is positioned in a region where a bending curvature of the two rods is greatest.

[0016] Wherein, a free end of each of the rod of the reinforcing structure is either integrally formed or connected via a bent rod to form a connection part.

[0017] Wherein, the connection part connects any two of the rods of different reinforcing structures.

[0018] Wherein, the connection part connects any two of the rods of the same reinforcing structure.

[0019] Wherein, the reinforcing structure is a continuous wave-shaped structure, and the wave-shaped structure comprises a U-shape or a V-shape.

[0020] Wherein, the reinforcing structure is a discontinuous structure with multiple components, and the configuration of the reinforcing structure comprises a rod-shaped or plate-shaped form.

[0021] Wherein, each of the rod of the reinforcing structures is laterally interconnected between different layers, and the interconnection is achieved by fusion bonding into an integral unit or by an interlocking arrangement.

[0022] Wherein, at least one of the reinforcing structure is an elastomer, and the material of the elastomer comprises one or a combination of thermoplastic elastomer (TPE), silicone rubber, thermoplastic polyurethane (TPU), neoprene, or polyester elastomer.

[0023] Wherein, the material of each of the rod comprises a composite material, a polymer (plastic), a metal, or multiple fiber bundles coated with a thermoplastic resin.

[0024] Wherein, the thermoplastic resin comprises one or a combination of the following polymers: polyamide (PA), polypropylene (PP), polyester (PET), polycarbonate (PC), polyimide (PI), polytetrafluoroethylene (PTFE), polyethylene (PE), polystyrene (PS), polymethyl methacrylate (PMMA), polyoxymethylene (POM), polyurethane (PU), polyvinyl alcohol (PVA), vinylon, polyethersulfone (PES), polyetheretherketone (PEEK), thermoplastic polyester elastomer (TPEE), styrene-based elastomer (TPS), thermoplastic polyamide elastomer (PAE), acrylonitrile butadiene styrene (ABS), polyphenylene sulfide (PPS), polysulfone (PSU), liquid-crystalline polymer (LCP), polyetherimide (PEI), polyamide-imide (PAI), polybutylene terephthalate (PBT), polyphenylene ether (PPE), acrylonitrile-styrene-acrylate (ASA), cellulose acetate (CA), thermoplastic polyurethane (TPU), ethylene-vinyl acetate copolymer (EVA), polyvinyl chloride (PVC), styrene copolymer (MS), or any combination thereof.

[0025] Wherein, the material of the fiber bundle comprises glass fiber, carbon fiber, micro steel fiber, natural fiber, synthetic fiber, metal fiber, ceramic fiber, or a combination of any of the foregoing fiber materials.

[0026] Wherein, the reinforcing structure is a sole framework formed by mutually joining multiple corresponding connection points between multiple elastic units, wherein the sole framework connects the rods via at least a portion of the connection points to form the reinforced structure for footwear.

[0027] Wherein, the reinforcing structure is manufactured by following steps: at least partially heating one or more continuous fiber bundles to render the continuous fiber bundles deformable, and bending each of the continuous fiber bundles in three dimensions along its longitudinal axis in space to form multiple elastic units, wherein the continuous fiber bundles comprise multiple continuous fibers and a thermoplastic resin covering the continuous fibers; and mutually joining multiple corresponding connection points between the elastic units to form the sole framework.

[0028] Wherein, at least a portion of the sole framework is covered with a covering material to form a continuous fiber structured sole.

[0029] Based on the above description, it is clear that the present invention achieves the following advantages:

[0030] 1. The reinforced structure for footwear achieves enhanced structural strength and support through the provision of the reinforcing structure on the rod. The reinforcing structure can effectively disperse the pressure or impact applied to the rod, thereby reducing the risk of excessive deformation or breakage in high-stress or high-strain regions of the rod. The reinforced structure for footwear is particularly suitable for applications that require withstanding relatively high pressure or demand higher protective performance.

[0031] 2. The reinforcing structure, positioned to protrude on one side of the rod, reduces the deformation in high-stress or high-strain regions of the rod where curvature is greatest. This further prevents the rod from easily breaking, providing enhanced support. At the same time, the curved surface of the reinforcing structure delivers elasticity to the reinforced structure for footwear.

[0032] 3. The reinforcing structure, positioned coplanar with the gap, allows pressure to be rapidly and evenly distributed through the reinforcing structure to the rod or the reinforcing structure itself, providing overall comfort and adaptability to the reinforced structure for footwear.

[0033] 4. By using multiple layers of the rods, when applied to a shoe sole, the overall sole thickness can be reduced while still providing high elastic support, rigid support, and multidirectional resilience.

[0034] 5. Since the rods are interconnected by the reinforcing structure, when under load, the sole not only provides elastic support along the lengthwise direction, but also allows lateral expansion and rebound, thereby offering the sole multidirectional deformable elasticity.

[0035] 6. The rods can adopt various wave-shaped forms, enabling the sole to provide different rigidity support and rebound capabilities in different areas. Due to the simple structure and excellent strength, the sole can offer diversified designs with varying regional rigidity support and rebound performance, even while maintaining a reduced weight.

[0036] 7. The reinforced structure for footwear forms the sole framework by bending the thermoplastic continuous fiber composite in three-dimensional space. The arrangement of the elastic units offers a very high degree of freedom, allowing the sole framework to be tailored according to user requirements and foot shape, enabling highly customized sole and meeting the demands of various application scenarios.

[0037] 8. The reinforced structure for footwear forms interwoven, supportive, and interconnected elastic units through the bending of continuous fiber bundles, which enhances the rigidity of the sole structure while reducing the amount of sole material used, thereby achieving a lightweight design for the footwear.

[0038] 9. By pre-joining the connection points of the elastic units before hot press molding, the heating temperature required for hot press forming of the continuous fiber structured sole can be reduced, thereby achieving significant energy savings.

[0039] 10. The continuous fiber structured sole provided by the present invention, by pre-joining the connection points of the elastic units before hot-press molding, allows the heating temperature required for hot press molding to be lowered, avoiding heating the entire sole structure above the melting point of the thermoplastic resin, which would cause displacement of the continuous fibers as well as damage to the fiber bundle impregnation structure and surface structure, thereby reducing the strength of the continuous fiber composite structure, and also reduces the time and cost required for secondary processing.

[0040] 11. The continuous fiber structured sole, by pre-joining the connection points of the elastic units before hot press molding, allows the heating temperature required for hot-press molding to be lowered, can significantly reduce the time needed for heating and cooling, greatly increase manufacturing efficiency, and, by reducing the temperature differential, decrease deformation of the hot press mold, thereby substantially extending the service life of the hot press mold.

[0041] 12. By pre-joining the connection points of the elastic units before hot press molding, the continuous fiber structured sole reduces the heating temperature required for hot-press molding, allowing for more flexible selection of mold materials, and lowering the high mold costs and process improvement expenses typically caused by the conventional high temperature molding process, which demands mold materials with high melting points and low thermal deformation.BRIEF DESCRIPTION OF THE DRAWINGS

[0042] FIG. 1 is a schematic diagram of an embodiment in accordance with the present invention;

[0043] FIG. 2 is a schematic diagram of a first embodiment in accordance with the present invention;

[0044] FIG. 3 is a schematic diagram of a second embodiment in accordance with the present invention;

[0045] FIG. 4 is a schematic diagram of a third embodiment in accordance with the present invention;

[0046] FIG. 5 is a schematic diagram of a fourth embodiment in accordance with the present invention;

[0047] FIG. 6 is a schematic diagram of a fifth embodiment in accordance with the present invention;

[0048] FIG. 7 is a schematic diagram of a sixth embodiment and a seventh embodiment in accordance with the present invention;

[0049] FIG. 8 is a schematic diagram of an embodiment in accordance with the present invention;

[0050] FIG. 9 is a schematic step diagram of an embodiment in accordance with the present invention.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0051] To more clearly illustrate the technical solutions of the embodiments of the present invention, brief introductions to the drawings used in the following descriptions of the embodiments are provided below. It is apparent that the drawings described below are merely some examples or embodiments of the present invention. Those of ordinary skill in the art may, without creative effort, apply the present invention to other similar situations based on these drawings. Unless clearly indicated otherwise by the context or separately specified, identical reference numerals in the drawings denote identical structures or operations.

[0052] As used in the present invention and the claims, unless the context clearly indicates otherwise, terms such as “a,”“an,”“one,” or “the” are not limited to the singular and may also encompass the plural. In general, the terms “comprise” and “include” indicate the inclusion of the stated steps or elements but do not exclude the presence of other steps or elements not expressly listed.

[0053] Flowcharts are used in the present invention to illustrate operations performed by a system according to embodiments of the invention. It should be understood that the preceding or subsequent operations are not necessarily executed in the exact order described. On the contrary, steps may be executed in reverse order or concurrently. Additionally, other operations may be added to these processes, or one or more steps may be removed from these processes.

[0054] With reference to FIG. 2, a first preferred embodiment of the present invention is shown. The present invention provides a reinforced structure for footwear, including at least one rod 10 and a reinforcing structure 20.

[0055] With reference to FIGS. 1 to 6, at least one rod 10 is a composite material fiber, and at least one rod 10 is bent with respect to a horizontal plane P, while corresponding to a longitudinal direction and a bending pattern, and further may correspond to a foot design. In particular, at least a portion of at least one rod 10 may optionally protrude in a bent manner toward the horizontal plane P. Alternatively, at least a portion of at least one rod 10 may protrude in a bent manner relative to the horizontal plane P. When at least one rod 10 receives a pressure from the horizontal plane P, a bending amplitude of at least one rod 10 decreases and at least one rod 10 deforms to extend in the longitudinal direction.

[0056] With reference to FIGS. 2 and 3, in first and second preferred embodiments in accordance with the present invention, one rod 10 is bent to form a frame, and an angle is formed between any two sections of the rod 10. A gap 11 is formed between the two sections of the rod 10.

[0057] With reference to FIGS. 4 to 6, in third to fifth preferred embodiments in accordance with the present invention, multiple rods 10 are arranged in a spaced or staggered manner, and a gap 11 is formed between at least two rods 10. Each rod 10 is elongated and arranged at intervals to form a lattice state. An elongated direction of each rod 10 defines the longitudinal direction of each rod 10, and a width direction is perpendicular to the longitudinal direction of each rod 10.

[0058] Wherein, at least a portion of the surface of each rod 10 is aligned with a plane.

[0059] Wherein, at least a portion of the surface of at least two rods 10 is aligned with a plane (see region A in FIGS. 5 and 6).

[0060] Wherein, at least a portion of two adjacent rods 10 defines a height difference between thereof.

[0061] Wherein, at least two of the multiple rods 10 are respectively bent relative to the horizontal plane P with different bending manner or bending amplitudes. An angle is formed between any two sections of at least one of multiple rod 10. Said staggered manner of arrangement may be formed by the multiple rods 10 being interlaced or intertwined in any manner to form a mesh-like structure.

[0062] In this regard, the plane defined from at least a portion of the surface of at least two rods 10 allows the at least two rods 10 may extend more coordinately in the longitudinal direction when the plane receiving pressure from a foot, distribute the foot pressure, and may increases increasing the overall stability of the rod 10 evenly.

[0063] By arranging the multiple rods 10, not only can the overall elastic compliance to applied pressure be enhanced, but reinforcement can also be applied to specific areas as needed. For example, more rods 10 may be arranged in a primary pressure-bearing region, or the size of the gap 11 may be adjusted in the primary pressure-bearing region.

[0064] With reference to FIG. 4 of a third preferred embodiment of the present invention, the multiple rods 10 are arranged in a staggered manner to collectively form a curved surface.

[0065] Further, after bending, the two ends of the rod 10 correspond to one end in the longitudinal direction, and an opening is formed between the two ends. The bended rod 10 to also bear pressure from other directions, different from the horizontal plane P, exhibiting more flexible elastic deformation capability.

[0066] Each of the rods 10 may be linear, wavy, or curved, and the material of each rod 10 is not limited. The rod 10 may be made of composite materials, polymers (plastics), metals, or the like, providing the rod 10 with the ability to bend in the longitudinal or width directions, thereby offering elasticity against applied pressure. When the rod 10 is disposed within a sole (not shown in the figures), the rod 10 provides elastic deformation when stepped on by a user. Further, the rod 10 includes multiple fiber bundles and a thermoplastic resin covering the fiber bundles. The rod 10 can be processed by locally heating to soften a region, bending it into the desired shape, and then cooling the heated region to form a fixed shape and structure, thereby establishing the bending amplitude of the rod 10.

[0067] The multiple rods 10 may be arranged in a staggered manner before or after the bending process to form a mesh-like structure.

[0068] The cross-section of the multiple rods 10 is not limited. For example, at different positions along the longitudinal direction, different widths or cross-sectional shapes may be provided to give varying rigidity and elasticity to different sections of the rods 10.

[0069] Further, the spacing between the multiple rods 10 may have different densities, which can correspond to the design of the foot contour. When the foot is subjected to different forces or pressures, the support strength and elasticity can be adjusted according to the needs of the foot. For example, a higher density may be provided in the arch region to enhance support, whereas a lower density may be provided in the heel region to increase comfort and flexibility of the foot.

[0070] Further, diameters for each of multiple rods 10 are not limited in this invention. The diameter may gradually increase or decrease to accommodate the pressure distribution at different regions of the foot.

[0071] With reference to FIG. 6, in sixth preferred embodiment of the present invention, a free end of the rod 10 may be integrally formed or connected with the other rod 10 to form a connection part 12. The connection part 12 can effectively distribute the pressure exerted on the foot during walking or exercise, and the pressure than can be evenly distributed between two adjacent rods 10, thereby reducing the load on specific areas of the foot and lowering the risk of injury of the user. Further, the connection part 12 can also reduce the deformation of two adjacent rods 10 during twisting and facilitate the rods 10 to return to their original shape, significantly extending the service life of the rods 10. The connection part 12 may connect the same or different rods 10. As shown in FIG. 6, the connection part 12 connects different rods 10.

[0072] The material of the fiber bundles includes glass fibers, carbon fibers, micro steel fibers, natural fibers, synthetic fibers, metal fibers, ceramic fibers, or a combination of the aforementioned fiber materials.

[0073] The thermoplastic resin includes polyamide (PA), polypropylene (PP), polyester (PET), polycarbonate (PC), polyimide (PI), polytetrafluoroethylene (PTFE), polyethylene (PE), polystyrene (PS), polymethyl methacrylate (PMMA), polyoxymethylene (POM), polyurethane (PU), polyvinyl alcohol (PVA), vinylon, polyethersulfone (PES), polyether ether ketone (PEEK), thermoplastic polyester elastomer (TPEE), styrene-based elastomer (TPS), thermoplastic polyamide elastomer (PAE), acrylonitrile butadiene styrene (ABS), polyphenylene sulfide (PPS), polysulfone (PSU), liquid crystal polymer (LCP), polyetherimide (PEI), polyamide-imide (PAI), polybutylene terephthalate (PBT), polyphenylene ether (PPE), acrylonitrile-styrene-acrylic (ASA), cellulose acetate (CA), thermoplastic polyurethane (TPU), ethylene-vinyl acetate copolymer (EVA), polyvinyl chloride (PVC), methyl styrene copolymer (MS), or one or a combination of the aforementioned polymer materials.

[0074] With reference to FIGS. 2 to 4, the reinforcing structure 20 may be rod-shaped or plate-shaped. Preferably, the reinforcing structure 20 is flexible, which can be achieved by selecting an appropriate material or by heating and / or pressing to achieve flexibility, followed by bending and forming. Further, the reinforcing structure 20 is joined to at least a portion of at least one rod 10 via a coupling part 21. The optional position of the reinforcing structure 20 may be within the gap 11, may extend along the entire longitudinal range of at least one rod 10, may be joined coplanar with the gap 11, may protrude in the direction opposite to the bending direction of at least one rod 10, or both at least one rod 10 and the reinforcing structure 20 may be concavely bent in the bending direction, wherein the bending amplitude of the reinforcing structure 20 is smaller than that of at least one rod 10.

[0075] With reference to FIG. 2 showing the first preferred embodiment in accordance with the present invention, the reinforcing structure 20 is plate-shaped. At least a portion of at least one rod 10 protrudes in a bent manner relative to the horizontal plane P, and its two ends correspond to one end in the longitudinal direction, being joined to form a closed frame. At the same time, the gap 11 is formed between the two ends of the bent at least one 10. Further, the reinforcing structure 20 extends along the longitudinal direction, and two coupling parts 21 are joined to the two ends of at least one rod 10 along the longitudinal direction. Both at least one rod 10 and the reinforcing structure 20 are concavely bent in the bending direction, and the bending amplitude of the reinforcing structure 20 is smaller than that of at least one rod 10.

[0076] In this way, when the reinforced structure for footwear is subjected to pressure perpendicular to the horizontal plane P, the bending amplitude of each rod 10 decreases and each rod 10 deforms to extend in the longitudinal direction. At the same time, the coupling part 21, due to its relatively large area, bears the pressure, allowing the coupling part 21 to undergo cushioning deformation and transmit part of the pressure to the reinforcing structure 20. The reinforcing structure 20 supports each rod 10, thereby reducing the deformation amplitude of each rod 10 and preventing the risk of rod breakage, while enhancing the support of the reinforced structure for footwear. Furthermore, the reinforcing structure 20 can evenly distribute the pressure to avoid concentration of the pressure, preventing the reinforced structure for footwear from experiencing elastic fatigue or permanent deformation at a single point, thereby extending the service life of the reinforced structure for footwear.

[0077] With reference to FIG. 3 showing the second embodiment in accordance with the present invention, the reinforcing structure 20 may also be disposed coplanar with the gap 11, so that each rod 10 and the reinforcing structure 20 have the same bending amplitude. When the reinforced structure for footwear is used as an insole, the reinforcing structure 20 may optionally be disposed in regions primarily subjected to pressure from the foot.

[0078] In this way, when the reinforced structure for footwear is subjected to pressure perpendicular to the horizontal plane P, each rod 10 and the reinforcing structure 20 can directly and evenly distribute the pressure throughout. Further, this quickly reduces the deformation in high-stress or high-strain regions of each rod 10, providing the reinforced structure for footwear with improved extensibility, thereby enabling the structure to achieve both support and elastic deformation adaptability under pressure.

[0079] With reference to FIG. 4 showing the third preferred embodiment in accordance with the present invention, multiple rods 10 are arranged with spacing, and the reinforcing structure 20 is connected in the gap 11 between two adjacent rods 10. The reinforcing structure 20 is disposed in the region of maximum bending amplitude between the two rods 10 and is arranged coplanar with the gap 11. In this way, when the reinforced structure for footwear is subjected to pressure, the reinforcing structure 20, due to its large area, first absorbs the impact and distributes the impact to other regions, reducing the risk of fracture in high-stress or high-strain regions of multiple rods 10, and significantly enhancing the protection capability of multiple rods 10 against the impact.

[0080] With reference to FIGS. 5 and 6 showing fourth and fifth preferred embodiments in accordance with the present invention, the reinforcing structure 20 is continuously disposed in the width direction between each rod 10. The reinforcing structure 20 may be a continuous wavy structure or a discontinuous structure with multiple components, enhancing the coupling rigidity of each rod 10 and providing elasticity when each rod 10 is subjected to pressure, thereby preventing fracture of each rod 10. Each rod 10 in different layers are connected laterally, which may be integrally fused or engaged in a snap-fit arrangement, as shown in FIG. 8.

[0081] The wavy structure of the reinforcing structure 20 may be U-shaped or V-shaped, wherein the openings of the wavy structure are arranged in an alternating manner.

[0082] When each rod 10 receive pressure from the foot, the reinforcing structure 20 extends in the width direction between the gaps. During this process, due to the material properties or structural elasticity of the reinforcing structure 20, the pressure from the foot can be effectively absorbed and dispersed, thereby reducing fatigue and discomfort experienced by the foot during walking or running, and providing improved athletic performance. After the foot pressure is released, the reinforcing structure 20 allows the reinforced structure for footwear to quickly return to its original shape, providing good support for the foot while enhancing overall comfort and durability.

[0083] The wavy design of the reinforcing structure 20 provides the foot with improved adaptability to different ground conditions. During various gait patterns or types of movement, the reinforcing structure 20 can provide different levels of elasticity and support according to the motion of the foot, thereby offering more stable foot conformity. Furthermore, during intense physical activity, the reinforcing structure 20 can prevent excessive forward and backward extension of each rod 10, thereby avoiding misalignment. This not only further enhances the anti-slip performance of the reinforced structure for footwear, allowing it to better accommodate foot torsion, but also reduces the risk of fracture of each rod 10.

[0084] According to the foregoing, the reinforced structure for footwear can significantly enhance elasticity, support, and adaptability of the foot to different gait patterns, while reducing energy loss during various activities and lowering pressure concentration on specific areas of the foot. This effectively disperses the pressure applied by the foot, thereby reducing fatigue and the risk of injury. Furthermore, the structure enables each rods 10 to better adapt to uneven surfaces, allowing the foot to perform a wider range of movements without discomfort, further improving overall foot adaptability.

[0085] With reference to FIG. 7 showing the sixth and seventh preferred embodiments in accordance with the present invention, the reinforced structure for footwear includes multiple rods 10 with different bending configurations. Multiple rods 10 have varying bending states, and the reinforcing structure 20 is designed to correspond to the foot. Multiple rods 10 exhibit a continuously undulating bending pattern, with at least a portion formed in a common plane. Alternatively, the reinforced structure for footwear may include multiple rods 10 that all have a continuous wavy structure, wherein the openings of the wavy structure are arranged in an alternating manner.

[0086] The material of the reinforcing structure 20 is not limited, provided that it is lightweight, supportive, elastic, and impact-resistant, and may fall within the scope of the present invention. The material may include polycarbonate (PC), polyethylene (PE), polypropylene (PP), rubber, ethylene-vinyl acetate (EVA), polyurethane (PU), silicone, carbon fiber composite (CFC), glass fiber composite (FGC), polyester (PES), polyurethane foam (PUF), aramid fiber (AF), polymer coatings, polytetrafluoroethylene (PTFE), or one or a combination of the foregoing polymer materials. Preferably, the reinforcing structure 20 is an elastomer, including thermoplastic polyester elastomer (TPEE), thermoplastic elastomer (TPE), thermoplastic styrene-based elastomer (TPS), thermoplastic polyamide elastomer (PAE), silicone rubber, polyurethane elastomer (TPU), neoprene, polyester elastomer, or one or a combination of the foregoing polymer materials.

[0087] The bending of multiple rods 10 and the reinforcing structure 20 may be performed manually using hand tools such as pliers, hammers, or nails, or mechanically using equipment such as rolling machines, bending machines, or shearing machines, to form the rods 10 and the reinforcing structure 20 into the desired shape.

[0088] The coupling part 21 may join the rod 10 and the reinforcing structure 20 by methods such as heating and pressing, welding, or adhesion.

[0089] The reinforcing structure 20 can provide elasticity and support. In this way, when the rod 10 is subjected to pressure perpendicular to the virtual plane A, the pressure can be distributed to the reinforcing structure 20, preventing the rod 10 from directly bearing the impact and structural failure.

[0090] With reference to FIG. 9 showing the eighth preferred embodiment in accordance with the present invention, the reinforcing structure 20 may form a shoe sole framework by interconnecting multiple connection points corresponding to multiple elastic units. At least a portion of these connection points is connected to the rod 10 to form the reinforced structure for footwear.

[0091] The manufacturing steps of the multiple elastic units include Step S10 through Step S40.

[0092] Step S10: At least a portion of one or more continuous fiber bundles is heated to allow the continuous fiber bundle to deform, and each of the continuous fiber bundles is bent in space in its axial direction in three dimensions, thereby forming multiple elastic units. The continuous fiber bundle includes multiple continuous fibers and a thermoplastic resin covering the continuous fibers. In Step S10, by locally heating at least a portion of the continuous fiber bundle and bending the continuous fiber bundle in three-dimensional directions with respect to its fiber axis, the thermoplastic resin covering the continuous fiber bundle and cured in shape is softened at the locally heated portion. At this time, the locally heated portion becomes flexible without fracture, and is bent in three-dimensional space. After the locally heated portion is cooled, an elastic unit having structural elasticity is formed. As used herein, the term “covering” includes, but is not limited to, processes such as impregnation and co-extrusion, whereby the thermoplastic resin is fully attached to the continuous fibers. In one embodiment, the continuous fibers are bundled and impregnated with the thermoplastic resin so that the thermoplastic resin adheres to and covers the continuous fibers, thereby forming a composite material of the continuous fiber bundle, which is then cooled and solidified.

[0093] The fiber material of the continuous fibers constituting the continuous fiber bundle includes carbon fibers, glass fibers, aramid fibers, ceramic fibers, or a combination of the above fiber materials. The term “continuous fiber bundle” refers to a bundle formed by assembling a plurality of continuous fiber yarns, wherein the fiber yarns of the continuous fibers maintain a continuity in the length direction of at least 2 cm or more. Preferably, the continuous fibers are fiber yarns having a length exceeding 10 cm; more preferably, the continuous fiber bundle has a length exceeding 1 m; and even more preferably, a majority of the continuous fibers are fiber yarns having a length equal to the longitudinal axis length of the continuous fiber bundle.

[0094] The term “bending in three-dimensional space” refers to the continuous fiber bundle being bendable along any direction of its longitudinal axis, and is not limited to a case where one bend must lie in a common plane with any two other bends. The bending may be performed manually, for example, by hand bending or using hand tools such as pliers, hammers, or nails to bend the continuous fiber bundle into a desired shape; or mechanically, for example, by using mechanical equipment such as a rolling machine, a bending machine, or a shearing machine to bend the continuous fiber bundle into the desired shape; or by guiding and feeding the continuous fiber bundle into a mold such that the continuous fiber bundle is bent in accordance with the shape of the mold. In addition, the bending also includes changing the cross-sectional shape of the continuous fiber bundle, such that at least a portion of the cross-section of the elastic unit formed by bending presents a circular shape, an elliptical shape, a square shape, a crescent shape, or a U-shape. The bending may alter the overall cross-sectional shape of the continuous fiber bundle or may only alter a portion of the cross-sectional shape of the continuous fiber bundle.

[0095] The term “elastic unit” in the present invention refers to an elastic structure capable of significantly absorbing an external vibration or an external force in one direction, which may be used for impact mitigation and vibration reduction. The elastic unit is formed by bending the continuous fiber bundle into a mechanical structure, and the deformation of the structure corresponding to the direction of the external force stores energy, thereby achieving significant absorption of the external vibration or the external force to accomplish the effect of impact mitigation and vibration reduction. In addition, under impacts within a certain range, the deformation of the elastic unit is reversible, namely, after being deformed by the external vibration or the external force, the elastic unit restores to its original structure once the external vibration or the external force is removed, without generating permanent deformation. Preferably, the elastic unit structure comprises a wave spring structure or a compression spring structure. The term “wave spring structure” in the present invention refers to an elastic structure with a wave-shaped configuration formed by bending the continuous fiber bundle. The wave spring structure includes, but is not limited to, a ring-shaped and closed wave spring structure, a ring-shaped and open wave spring structure, or a linear wave spring structure, as well as combinations thereof. Examples include a laminated wave spring structure formed by overlapping crests and troughs of multiple ring-shaped wave spring structures, or an opposed wave spring structure formed by joining the crests of multiple ring-shaped wave spring structures. The term “compression spring structure” in the present invention refers to a structure having a plurality of helical coils formed by bending the continuous fiber bundle, wherein a gap between the helical coils varies in response to the external vibration or the external force. The helical coils of the compression spring structure are not limited in configuration, and the compression spring structure may exhibit linear or nonlinear compression deformation behavior.

[0096] Furthermore, the respective elastic units generated by locally heating and bending the respective continuous fiber bundles may have identical or different structural shapes. In some cases, part or all of the elastic units may be formed by connecting the head and tail of the original continuous fiber bundle, thereby forming a closed annular structure. The annular structure may be a deformed annular shape and may have different winding numbers. In one embodiment, some of the elastic units comprise multiple intersection points, and spiral or braided windings may be present within the elastic unit or between the elastic units.

[0097] In applications involving multiple of the continuous fiber bundles, the respective elastic units generated by the respective continuous fiber bundles may have completely identical shapes and structures, partially identical shapes and structures, or completely different shapes and structures. In addition, the fiber bundle materials of the different continuous fiber bundles and the thermoplastic resin components covering the same may be identical or different, such that the fiber bundle materials and the thermoplastic resin components of the elastic units formed by the respective continuous fiber bundles may be identical or different, thereby creating structural units having identical or different material properties.

[0098] Step S20: Multiple corresponding points between the respective elastic units are joined to each other to form a sole framework. The term “joined to each other” refers to at least two corresponding connection points being fixed together through joining. The connection point may be a local point of one elastic unit that is fixed to another connection point. The joining of at least two corresponding connection points may be a joining between two or more connection points within the same elastic unit, or between different connection points located on two or more elastic units. The term “joining” refers to a process in which two or more connection points are fixed together to become integral. Furthermore, the joining of the plurality of connection points also includes a mode in which multiple successive connection points are joined to form a linear or even planar joining. In a preferred embodiment, the head and tail ends of the continuous fiber bundle forming the elastic unit are joined to each other, such that the elastic unit does not have an obvious endpoint.

[0099] The method of joining in step S20 includes, but is not limited to, welding, fusing, soldering, compression joining, or adhesive bonding. Furthermore, the at least two corresponding and mutually contacting connection points can be locally heated to a temperature above the melting point of the thermoplastic resin of the respective connection points, and maintained in contact until the locally heated area cools and the thermoplastic resin coating solidifies, thereby joining the connection points into a single unit.

[0100] Step S30 (optional): Form at least a portion of the outsole framework using a hot press mold.

[0101] In this step S30, at least a portion of the outsole structure formed in step S20 is placed into a cavity of the hot press mold. After closing the hot press mold, pressure and heat are applied to soften and bend the outsole structure, thermoplastically forming it into the final shape with the desired curved surface and surface pattern. The hot press mold is then cooled to solidify the thermoplastic resin, after which the formed outsole framework can be removed.

[0102] Preferably, the heating of the hot press mold does not exceed the melting point of the thermoplastic resin. Heating below the resin's melting point prevents the encapsulated continuous fiber bundles from shifting within the hot press mold, which could otherwise compromise product quality, cause loss of fine structural details, or necessitate secondary processing. Wherein, the heat supplied to the hot press mold raises the temperature above the glass transition temperature of the thermoplastic resin. More preferably, the heating temperature exceeds the heat deflection temperature of the thermoplastic resin but remains below its melting point. For an outsole structure composed of two or more thermoplastic resins with different components, the heating temperature of the hot press mold should not exceed the highest melting point among the resins. Since the elastic units within and between the outsole structure are already pre-joined, the heat required for the hot press mold can be significantly lower than that used in conventional high temperature molding, and the placement of the mold can be more flexibly planned. Heating may be applied only to areas of the outsole structure's surface that require shaping or reinforcement of the connection points. Preferably, the outsole framework need not be fully conformed to the hot press mold; it may be partially fitted to the hot press mold surface to preserve the structural characteristics of the elastic units.

[0103] Step S40: At least a portion of the outsole framework is coated with a covering material to form a continuous fiber structured outsole. The covering material further reinforces and protects the outsole framework. The outsole framework creates a skeleton with relatively high rigidity along the axial direction of the continuous fiber bundles, and, combined with the externally applied covering material, provides cushioning when the continuous fiber bundles are subjected to forces in the radial direction, preventing fracture of the continuous fiber composite structure and providing a more comfortable experience for the user's foot. The covering material may be an elastomer, foam material, porous material, or resin material. The resin material may be a thermosetting or thermoplastic resin. If the resin material is a thermoplastic resin, it may have the same or different composition as the thermoplastic resin covering the outsole framework. Further, the resin material may contain fibers, which can be continuous fibers or short fibers. More preferably, the covering material may be a thermoplastic polyurethane, ethylene-vinyl acetate copolymer, rubber, or polyolefin.

[0104] Further, Step S40 may be performed multiple times. For example, the covering material may first be applied to coat a portion of the outsole structure, and then a covering material of a different type may be applied to coat another portion of the outsole structure, thereby achieving different covering materials in different regions of the outsole and creating a continuous fiber structured outsole with multiple levels of strength distribution and visual effects.

[0105] Based on the above description, the present invention achieves the following advantages:

[0106] 1. The reinforced structure for footwear achieves enhanced structural strength and support through the provision of the reinforcing structure 20 on the rod 10. The reinforcing structure 20 can effectively disperse the pressure or impact applied to the rod 10, thereby reducing the risk of excessive deformation or breakage in high-stress or high-strain regions of the rod 10. The reinforced structure for footwear is particularly suitable for applications that require withstanding relatively high pressure or demand higher protective performance.

[0107] 2. The reinforcing structure 20, positioned to protrude on one side of the rod 10, reduces the deformation in high-stress or high-strain regions of the rod 10 where curvature is greatest. This further prevents the rod 10 from easily breaking, providing enhanced support. At the same time, the curved surface of the reinforcing structure 20 delivers elasticity to the reinforced structure for footwear.

[0108] 3. The reinforcing structure 20, positioned coplanar with the gap 11, allows pressure to be rapidly and evenly distributed through the reinforcing structure 20 to the rod 10 or the reinforcing structure 20 itself, providing overall comfort and adaptability to the reinforced structure for footwear.

[0109] 4. By using multiple layers of the rods 10, when applied to a shoe sole, the overall sole thickness can be reduced while still providing high elastic support, rigid support, and multidirectional resilience.

[0110] 5. Since the rods 10 are interconnected by the reinforcing structure 20, when under load, the sole not only provides elastic support along the lengthwise direction, but also allows lateral expansion and rebound, thereby offering the sole multidirectional deformable elasticity.

[0111] 6. The rods 10 can adopt various wave-shaped forms, enabling the sole to provide different rigidity support and rebound capabilities in different areas. Due to the simple structure and excellent strength, the sole can offer diversified designs with varying regional rigidity support and rebound performance, even while maintaining a reduced weight.

[0112] 7. The reinforced structure for footwear forms the sole framework by bending the thermoplastic continuous fiber composite in three-dimensional space. The arrangement of the elastic units offers a very high degree of freedom, allowing the sole framework to be tailored according to user requirements and foot shape, enabling highly customized sole and meeting the demands of various application scenarios.

[0113] 8. The reinforced structure for footwear forms interwoven, supportive, and interconnected elastic units through the bending of continuous fiber bundles, which enhances the rigidity of the sole structure while reducing the amount of sole material used, thereby achieving a lightweight design for the footwear.

[0114] 9. By pre-joining the connection points of the elastic units before hot press molding, the heating temperature required for hot press forming of the continuous fiber structured sole can be reduced, thereby achieving significant energy savings.

[0115] 10. The continuous fiber structured sole provided by the present invention, by pre-joining the connection points of the elastic units before hot-press molding, allows the heating temperature required for hot press molding to be lowered, avoiding heating the entire sole structure above the melting point of the thermoplastic resin, which would cause displacement of the continuous fibers as well as damage to the fiber bundle impregnation structure and surface structure, thereby reducing the strength of the continuous fiber composite structure, and also reduces the time and cost required for secondary processing.

[0116] 11. The continuous fiber structured sole, by pre-joining the connection points of the elastic units before hot press molding, allows the heating temperature required for hot-press molding to be lowered, can significantly reduce the time needed for heating and cooling, greatly increase manufacturing efficiency, and, by reducing the temperature differential, decrease deformation of the hot press mold, thereby substantially extending the service life of the hot press mold.

[0117] 12. By pre-joining the connection points of the elastic units before hot press molding, the continuous fiber structured sole reduces the heating temperature required for hot-press molding, allowing for more flexible selection of mold materials, and lowering the high mold costs and process improvement expenses typically caused by the conventional high temperature molding process, which demands mold materials with high melting points and low thermal deformation.

Claims

1. A reinforced structure for footwear, comprising:A rod, wherein at least a portion of the rod is curved either toward or away from a horizontal plane, and when the rod receives a pressure from the horizontal plane, the bending amplitude of the rod is reduced and the rod deforms in a longitudinal direction; anda reinforcing structure, coupled to at least a portion of the rod via a coupling part.

2. The reinforced structure for footwear according to claim 1, wherein an angle is formed between any two segments of the rod, a gap is formed between any two segments of the rod, the two ends of the rod correspond to respective ends in the longitudinal direction, and an opening is formed between the two ends.

3. The reinforced structure for footwear according to claim 1, wherein a second rod is arranged with spacing or in an interleaved manner from the rod, a gap is formed between the rod and the second rod, the rod and the second rod having an axis defining the longitudinal direction, the rod and the second rod defining a width direction perpendicular to the longitudinal direction, at least a portion of the rod and the second rod being formed in a common plane, and at least a portion of the longitudinal direction of the rod and the second rod forming a height difference.

4. The reinforced structure for footwear according to claim 3, wherein the reinforcing structure is continuously disposed in the width direction between the rod and the second rod, so that when the rod and the second rod receive pressure from the horizontal plane, the reinforcing structures, the rod and the second rod extend in the width direction.

5. The reinforced structure for footwear according to claim 3, wherein the second rod are bent in different bending directions or have different bending curvatures relative to the horizontal plane, wherein the rod and the second rod are arranged in an interlaced or intertwined manner to form a mesh-like structure, and wherein at least a portion of the rod and the second rod collectively form a curved surface.

6. The reinforced structure for footwear according to claim 2, wherein at least a portion of the reinforcing structure is disposed in the gap, and the reinforcing structure is coplanar with the gap.

7. The reinforced structure for footwear according to claim 3, wherein at least a portion of the reinforcing structure is disposed in the gap, and the reinforcing structure is coplanar with the gap.

8. The reinforced structure for footwear according to claim 2, wherein at least a portion of the reinforcing structure is disposed in the gap, and connects to at least one portion of the rod.

9. The reinforced structure for footwear according to claim 3, wherein at least a portion of the reinforcing structure is disposed in the gap, and the second rod protrudes relative to the bending direction.

10. The reinforced structure for footwear according to claim 8, wherein both the rod and the reinforcing structure are concavely curved toward the bending direction, and the bending amplitude of the reinforcing structure is smaller than the bending amplitude of the rod.

11. The reinforced structure for footwear according to claim 9, wherein both the second rod and the reinforcing structure are concavely curved toward the bending direction, and the bending amplitude of the reinforcing structure is smaller than the bending amplitude of the second rod.

12. The reinforced structure for footwear according to claim 8, wherein the reinforcing structure extends along the longitudinal direction of the rod, and the two coupling parts are connected to the rod at both ends in the longitudinal direction.

13. The reinforced structure for footwear according to claim 9, wherein the reinforcing structure extends along the longitudinal direction of the rod and the second rod, and the two coupling parts are connected to the rod and the second rod at both ends in the longitudinal direction.

14. The reinforced structure for footwear according to claim 1, wherein the reinforcing structure is disposed between the rod and the second rod, and the reinforcing structure is positioned in a region where a bending curvature of the rod and the second rod is greatest.

15. The reinforced structure for footwear according to claim 3, wherein a free end of the rod and the second rod of the reinforcing structure is either integrally formed or connected via a bent rod to form a connection part.

16. The reinforced structure for footwear according to claim 15, wherein the connection part connects to two portions of the second rod.

17. The reinforced structure for footwear according to claim 15, wherein the connection part connects to at least one portion of the rod or the second rod.

18. The reinforced structure for footwear according to claim 1, wherein the reinforcing structure is a continuous wave-shaped structure, and the wave-shaped structure comprises a U-shape or a V-shape.

19. The reinforced structure for footwear according to claim 1, wherein the reinforcing structure is a discontinuous structure with multiple components, and the configuration of the reinforcing structure comprises a rod-shaped or plate-shaped form.

20. The reinforced structure for footwear according to claim 19, wherein the rod and the second rod of the reinforcing structures is laterally interconnected between different layers, and the interconnection is achieved by fusion bonding into an integral unit or by an interlocking arrangement.

21. The reinforced structure for footwear according to claim 1, wherein at least one of the reinforcing structure is an elastomer, and the material of the elastomer comprises one or a combination of thermoplastic elastomer (TPE), silicone rubber, thermoplastic polyurethane (TPU), neoprene, or polyester elastomer.

22. The reinforced structure for footwear according to claim 1, wherein the material of the rod and the second rod comprises a composite material, a polymer (plastic), a metal, or multiple fiber bundles coated with a thermoplastic resin.

23. The reinforced structure for footwear according to claim 22, wherein the thermoplastic resin comprises one or a combination of the following polymers: polyamide (PA), polypropylene (PP), polyester (PET), polycarbonate (PC), polyimide (PI), polytetrafluoroethylene (PTFE), polyethylene (PE), polystyrene (PS), polymethyl methacrylate (PMMA), polyoxymethylene (POM), polyurethane (PU), polyvinyl alcohol (PVA), vinylon, polyethersulfone (PES), polyetheretherketone (PEEK), thermoplastic polyester elastomer (TPEE), styrene-based elastomer (TPS), thermoplastic polyamide elastomer (PAE), acrylonitrile butadiene styrene (ABS), polyphenylene sulfide (PPS), polysulfone (PSU), liquid-crystalline polymer (LCP), polyetherimide (PEI), polyamide-imide (PAI), polybutylene terephthalate (PBT), polyphenylene ether (PPE), acrylonitrile-styrene-acrylate (ASA), cellulose acetate (CA), thermoplastic polyurethane (TPU), ethylene-vinyl acetate copolymer (EVA), polyvinyl chloride (PVC), styrene copolymer (MS), or any combination thereof.

24. The reinforced structure for footwear according to claim 22, wherein the material of the fiber bundle comprises glass fiber, carbon fiber, micro steel fiber, natural fiber, synthetic fiber, metal fiber, ceramic fiber, or a combination of any of the foregoing fiber materials.

25. The reinforced structure for footwear according to claim 1, wherein the reinforcing structure is a sole framework formed by mutually joining multiple corresponding connection points between multiple elastic units, wherein the sole framework connects the rod via at least a portion of the connection points to form the reinforced structure for footwear.

26. The reinforced structure for footwear according to claim 25, wherein the reinforcing structure is manufactured by following steps:at least partially heating one or more continuous fiber bundles to render the continuous fiber bundles deformable, and bending each of the continuous fiber bundles in three dimensions along its longitudinal axis in space to form multiple elastic units, wherein the continuous fiber bundles comprise multiple continuous fibers and a thermoplastic resin covering the continuous fibers; andmutually joining multiple corresponding connection points between the elastic units to form the sole framework.

27. The reinforced structure for footwear according to claim 22, wherein at least a portion of the sole framework is covered with a covering material to form a continuous fiber structured sole.

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