Porous hygroscopic material production process, material and insole

Abstract

This disclosure discloses a porous hygroscopic material production process, material and insole; the porous hygroscopic insole comprises a microporous surface, a multi-microporous hygroscopic material layer, a breathable layer, and a high-resilience layer or breathable mesh frame; one end surface of the multi-microporous hygroscopic material layer is subjected to frosting treatment to obtain the microporous surface, and the multi-microporous hygroscopic material layer and the microporous surface are integrated to enhance a hygroscopic effect; the breathable layer is any one of porous breathable PU foam, two-component in-mold foaming PU foam, EVA foam, and latex foam. The breathable mesh frame is of a mesh frame structure formed by stacking cube-shaped cage frames manufactured by a 3D printer; the high-resilience layer or breathable mesh frame is integrally connected with the multi-microporous hygroscopic material layer. When a user walks with feet, a repeatably-rebounded highly-breathable space is formed, air circulation airflow operates repeatedly.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of rapid hygroscopic materials, in particular to a porous hygroscopic material production process, material and insole.BACKGROUND

[0002] At present, the types of insoles on the market are roughly divided into EVA foamed cold-pressing molded insoles, PU two-component injection molded insoles, and PU foamed hot-pressing molded insoles. Regardless of whether the material itself is breathable or not, such insoles are unable to rapidly absorb moisture and water. After the test, data of the water absorption effect of common commercially available insoles is shown in FIG. 1.

[0003] Therefore, there is an urgent need for a new material capable of achieving rapid and high hygroscopicity, and an insole using this material to solve the problem that the soles of users' feet are prone to dampness when wearing shoes and cannot be kept dry and comfortable, easily causing health and hygiene issues for the soles.SUMMARY

[0004] This disclosure is mainly directed at the above problems and proposes a porous hygroscopic material production process, material and insole, aiming to solve the technical problems in the background art.

[0005] To achieve the above purpose, this disclosure provides a porous hygroscopic material production process, comprising the following method steps:

[0006] preparing a fabric soaking solution: in parts by weight, mixing and stirring 100 parts of water-insoluble polyurethane resin, 5-20 parts of diatomaceous earth, 20-50 parts of bleached wood powder, 10-120 parts of solvent, 2-5 parts of surfactant and hygroscopic and sweat releasing auxiliary agent for 30 minutes, and then performing vacuum stirring for defoaming;

[0007] preparing a fabric coating solution: in parts by weight, mixing and stirring 100 parts of water-insoluble polyurethane resin, 5-20 parts of diatomaceous earth, 10-30 parts of bleached wood powder, 60-100 parts of solvent, 10-20 parts of colorant, 2-5 parts of surfactant and hygroscopic and sweat releasing auxiliary agent for 30 minutes, and then performing vacuum stirring for defoaming;

[0008] immersing a carrier braided layer into the fabric soaking solution, with a ratio of a weight of the fabric soaking solution to an area of the carrier braided layer being 300-400 g / m2 to obtain a first bonding layer; using a pressure device to pressurize the first bonding layer for dewatering to remove 90% of water; applying the fabric coating solution onto a surface of the first bonding layer at a ratio of the weight of the fabric coating solution to the area of the first bonding layer of 300-500 g / m2 by scraping or coating, so as to obtain a second bonding layer; using a pressure device to pressurize the second bonding layer for dewatering to remove water;

[0009] subjecting the second bonding layer to multi-stage water washing, then performing vacuum dehydration to remove water and residual solvent in the second bonding layer, and then conducting drying to obtain a multi-microporous hygroscopic material layer.

[0010] Furthermore, a surface treatment step is further included as follows: subjecting one end surface of the multi-microporous hygroscopic material layer to surface frosting treatment.

[0011] Further, a breathable layer is attached and connected to a surface of the multi-microporous hygroscopic material layer that is away from the end surface subjected to frosting treatment, and the breathable layer is any one of porous breathable PU foam, two-component in-mold foaming PU foam, EVA foam, and latex foam.

[0012] Furthermore, a manufacturing step of a high-resilience layer is further included as follows:

[0013] preparing an impregnation solution, which is water-soluble styrene butadiene rubber with a solid content of 31%;

[0014] immersing a high-resilience mesh fabric in the impregnation solution, followed by heating, drying, and cross-linking, cooling to obtain the high-resilience layer, and attaching and connecting one end surface of the high-resilience layer to the other end surface of the breathable layer.

[0015] Furthermore, a manufacturing step of a breathable mesh frame is further included as follows:

[0016] using the other end surface of the breathable layer as a connecting surface to receive and connect with the breathable mesh frame printed by a 3D printer, wherein the breathable mesh frame is of a mesh frame structure formed by stacking cube-shaped cage frames connected by a plurality of supporting rods with a diameter of 1 mm and a length of 2 mm.

[0017] Furthermore, a material recovery and treatment step is further included as follows: treating, recovering, and recycling coagulated and shed solid materials and drained and dehydrated wastewater liquid materials generated during the execution of the steps.

[0018] Furthermore, manufacturing steps of the carrier braided layer are as follows: performing napping and / or brushing on the carrier braided layer, then performing shearing, and then performing shaping in an environment at a temperature of 180° C. for 30 seconds;

[0019] or, a raw material of the carrier braided layer is a spunlace non-woven fabric with a thickness of 0.4-0.5 mm.

[0020] Further, the prepared fabric coating solution further contains 10-20 parts of colorant; both the fabric coating solution and the fabric coating solution have the diatomaceous earth with a fineness of 600 mesh and the bleached wood powder with a fineness of 400-600 mesh; prior to the step of using the pressure device to pressurize the first bonding layer for dewatering to remove 90% of the water, placing the first bonding layer in a coagulation tank with a water temperature of 40-50° C. for 20 seconds; a water washing duration of multi-stage water washing for the second bonding layer is 3-5 minutes; a drying temperature before obtaining the multi-microporous hygroscopic material layer is 160° C.; the high-resilience mesh fabric is a sandwich mesh fabric with a weight of 400 g / m2 and an upper-lower layer gap of not less than 4 mm; an impregnation amount of the sandwich mesh fabric with the impregnation solution is 50 g in dry weight, and a subsequent heating and drying temperature is 150° C.

[0021] A porous hygroscopic material, which is prepared by the porous hygroscopic material production process as described above.

[0022] A porous hygroscopic insole, comprising the porous hygroscopic material as described above, wherein the porous hygroscopic material is cut using a hot-pressing mold or a cold-pressing mold to form an insole.

[0023] Compared with the prior art, according to the porous hygroscopic material production process, material and insole provided by this disclosure, the material prepared by the production process and finished insole products have rapid and high water absorption performance, which can keep the user's feet dry and comfortable when the user wears shoes. A cooling effect can be kept at high temperatures in summer, and discomfort of the soles caused by sweating and dampness of the user is avoided.BRIEF DESCRIPTION OF DRAWINGS

[0024] FIG. 1 shows statistical data of tests for a water absorption effect of conventional commercially available common insoles.

[0025] FIG. 2 shows statistical data of tests for a water absorption effect of a porous hygroscopic material of the present application.

[0026] FIG. 3 is a schematic sectional view of a structure of Implementation I of a porous hygroscopic material produced by a porous hygroscopic material production process of the present application.

[0027] FIG. 4 is a schematic sectional view of a structure of Implementation II of a porous hygroscopic material produced by the porous hygroscopic material production process of the present application.

[0028] Reference numerals shown in the figures: 1. Multi-microporous hygroscopic material layer; 2. Microporous surface; 3. Breathable layer; 4. High-resilience layer; 5. Breathable mesh frame.DETAILED DESCRIPTION OF THE EMBODIMENTS

[0029] This implementation provides a porous hygroscopic insole, which adopts a porous hygroscopic material as described below, and the porous hygroscopic material is prepared by a porous hygroscopic material production process as described below; the porous hygroscopic material is cut using a hot-pressing mold or a cold-pressing mold to form an insole.

[0030] The porous hygroscopic insole comprises a microporous surface 2, a multi-microporous hygroscopic material layer 1, a breathable layer 3, and a high-resilience layer 4 or a breathable mesh frame 5; one end surface of the multi-microporous hygroscopic material layer 1 is subjected to frosting treatment to obtain the microporous surface 2, and the multi-microporous hygroscopic material layer and the microporous surface are integrated to enhance a hygroscopic effect; the breathable layer 3 is any one of porous breathable PU foam, two-component in-mold foaming PU foam, EVA foam, and latex foam. The breathable mesh frame 5 is of a mesh frame structure formed by stacking cube-shaped cage frames manufactured by a 3D printer; the high-resilience layer 4 or the breathable mesh frame 5 is integrally connected with the multi-microporous hygroscopic material layer 1. When a user walks with feet, a repeatably-rebounded highly-breathable space is formed, air circulation airflow operates repeatedly, and moisture adsorbed in the multi-microporous hygroscopic material layer 1 and the breathable layer 3 is discharged and volatilized, so that an automatically circulating comfortable space is formed inside a shoe, the feet of the user can be kept dry to generate comfort, and discomfort caused by sweating and dampness is avoided.

[0031] Benefiting from the adopted porous hygroscopic material, the porous hygroscopic insole provided by this disclosure can achieve rapid and high water absorption performance, which can improve and avoid the discomfort of the user's soles caused by sweat retention when the user wears shoes for a long time.

[0032] It should be noted that the porous hygroscopic insole can be either an independent insole unit assembled into shoes, or can be produced as an integrated and non-detachable structure with a sole of a shoe body, which is not limited herein.

[0033] With reference to FIGS. 1-4, this implementation provides a porous hygroscopic material production process, comprising the following method steps:

[0034] S01 preparing a fabric soaking solution: in parts by weight, mixing and stirring 100 parts of water-insoluble polyurethane resin, 5-20 parts of diatomaceous earth, 20-50 parts of bleached wood powder, 10-120 parts of solvent, 2-5 parts of surfactant, and a hygroscopic and sweat releasing auxiliary agent for 30 minutes to evenly disperse these materials such as diatom, wood powder, and colorant in a water-insoluble polyurethane resin slurry, and then performing vacuum stirring for defoaming;

[0035] S02 preparing a fabric coating solution: in parts by weight, mixing and stirring 100 parts of water-insoluble polyurethane resin, 5-20 parts of diatomaceous earth, 10-30 parts of bleached wood powder, 60-100 parts of solvent, 10-20 parts of colorant, 2-5 parts of surfactant, and a hygroscopic and sweat releasing auxiliary agent for 30 minutes to evenly disperse these materials such as diatom, wood powder, and colorant in a water-insoluble polyurethane resin mixed liquor, and then performing vacuum stirring for defoaming;

[0036] S03 immersing a carrier braided layer into the fabric soaking solution, with a ratio of a weight of the fabric soaking solution to an area of the carrier braided layer being 300-400 g / m2 to obtain a first bonding layer; using a pressure device to pressurize the first bonding layer for dewatering to remove 90% of water; applying the fabric coating solution onto a surface of the first bonding layer at a ratio of the weight of the fabric coating solution to the area of the first bonding layer of 300-500 g / m2 by scraping or coating, so as to obtain a second bonding layer; using a pressure device to pressurize the second bonding layer for dewatering to remove water;

[0037] S04 subjecting the second bonding layer to multi-stage water washing, then performing vacuum dehydration to remove water and residual solvent in the second bonding layer, and then conducting drying to obtain a multi-microporous hygroscopic material layer 1.

[0038] It should be noted that step S01 and step S02 can be executed without any particular order.

[0039] The second bonding layer is subjected to multi-stage water washing, wherein multi-stage water washing refers to the fact that the second bonding layer is sequentially placed in different water washing tanks for water washing multiple times.

[0040] S05 also comprising a surface treatment step as follows: subjecting one end surface of the multi-microporous hygroscopic material layer 1 to surface frosting treatment.

[0041] In some implementations, the pressure device is an extrusion wheel.

[0042] Through this step, a microporous surface 2 is obtained on one end surface of the multi-microporous hygroscopic material layer 1.

[0043] Preferably, the surface frosting treatment is performed by adopting two sanding procedures, so that the multi-microporous hygroscopic material layer 1 of a microporous and internal microporous highly hygroscopic and sweat releasing structure forms a whole, thereby enhancing the hygroscopic and sweat releasing effect, and enabling the multi-microporous hygroscopic material layer 1 to receive moisture and water more quickly and in larger quantities through the microporous surface 2.

[0044] S06 Attach and connect the breathable layer 3 to a surface of the multi-microporous hygroscopic material layer 1 that is away from the end surface subjected to frosting treatment; the breathable layer 3 is any one of porous breathable PU foam, two-component in-mold foaming PU foam, EVA foam, and latex foam.

[0045] When the porous breathable PU foam is selected as the breathable layer 3, this material is adopted as the raw material, and after the breathable layer 3 is attached and connected to the multi-microporous hygroscopic material layer 1, the insole can be pressed with a mold by using a mold heating or material heating cold-pressing process.

[0046] When the EVA foam is selected as the breathable layer 3, this material is adopted as the raw material, and after the breathable layer 3 is attached and connected to the multi-microporous hygroscopic material layer 1, the insole can be obtained by cold-pressing using a mold for material heating.

[0047] When the EVA foam is selected as the breathable layer 3, this material is adopted as the raw material, and after the breathable layer 3 is attached and connected to the multi-microporous hygroscopic material layer 1, the insole can be obtained by direct cutting.

[0048] The function of the multi-microporous hygroscopic material layer 1 is that rapid and high-capacity hygroscopicity and moisture absorption can be achieved, but the capacity is still limited. By using the breathable layer 3 as a matching component, the moisture absorbed in the multi-microporous hygroscopic material layer 1 can be volatilized to the outside through air flowing depending on the breathable layer 3. Therefore, the multi-microporous hygroscopic material layer 1 can continuously absorb moisture and volatilize water depending on the breathable layer 3, and the multi-microporous hygroscopic material layer 1 still has a dry part that can perform moisture absorption.

[0049] The test data of the water absorption effect of the porous hygroscopic material produced by this production process is shown in FIG. 2.

[0050] With reference to FIG. 3 for Implementation I

[0051] A manufacturing step of the high-resilience layer 4 is also included as follows:

[0052] preparing an impregnation solution, which is water-soluble styrene butadiene rubber with a solid content of 31%;

[0053] immersing a high-resilience mesh fabric in the impregnation solution, followed by heating, drying, and cross-linking, cooling to obtain the high-resilience layer 4, and attaching and connecting one end surface of the high-resilience layer 4 to the other end surface of the breathable layer 3.

[0054] With reference to FIG. 4 for Implementation II

[0055] S07 A manufacturing step of the breathable mesh frame 5 is also included as follows:

[0056] using the other end surface of the breathable layer 3 as a connecting surface to receive and connect with the breathable mesh frame 5 printed by a 3D printer, wherein the breathable mesh frame 5 is of a mesh frame structure formed by stacking cube-shaped cage frames connected by a plurality of supporting rods with a diameter of 1 mm and a length of 2 mm.

[0057] An integrated material formed by connecting and combining the aforementioned multi-microporous hygroscopic material layer 1 and the breathable layer 3 is placed into a 3D printer, and the breathable mesh frame 5 is printed and connected to the other end surface of the breathable layer 3; the breathable mesh frame 5 is a substitute solution for the high-resilience layer 4. The cross-sections of the supporting rods are different according to the different output holes of a print head of the 3D printer, and the supporting rods are preferably cylindrical rods.

[0058] S08 A material recovery and treatment step is further included as follows:

[0059] treating, recovering, and recycling coagulated and shed solid materials and drained and dehydrated wastewater liquid materials generated during the execution of the steps.

[0060] This step is green, low-carbon, and environmentally friendly, which promotes resource recycling and saves costs.

[0061] Manufacturing steps of the carrier braided layer are as follows: performing napping and / or brushing on the carrier braided layer, and then shearing to form flat and uniform naps on the fabric; then performing shaping in an environment at a temperature of 180° C. for 30 seconds to make a napped surface of the fabric stable;

[0062] or, a raw material of the carrier braided layer is a spunlace non-woven fabric with a thickness of 0.4-0.5 mm.

[0063] The prepared fabric coating solution further contains 10-20 parts of colorant; both the fabric coating solution and the fabric coating solution have the diatomaceous earth with a fineness of 600 mesh and the bleached wood powder with a fineness of 400-600 mesh; prior to the step of using the pressure device to pressurize the first bonding layer for dewatering to remove 90% of the water, placing the first bonding layer in a coagulation tank with a water temperature of 40-50° C. for 20 seconds; a water washing duration of multi-stage water washing for the second bonding layer is 3-5 minutes; a drying temperature before obtaining the multi-microporous hygroscopic material layer 1 is 160° C.; the high-resilience mesh fabric is a sandwich mesh fabric with a weight of 400 g / m2 and an upper-lower layer gap of not less than 4 mm; an impregnation amount of the sandwich mesh fabric with the impregnation solution is 50 g in dry weight, and a subsequent heating and drying temperature is 150° C.

[0064] The impregnation amount of the sandwich mesh fabric with the impregnation solution is 50 g in dry weight, which refers to the weight of substance in the impregnation solution contained in the sandwich mesh fabric converted from a liquid state to a solid state after the sandwich mesh fabric is combined with the impregnation solution and dried. The impregnation amount refers to the weight of the impregnation solution remaining on the woven fabric after per square meter of woven fabric is impregnated with the impregnation solution and pressed by the pressure device.

[0065] The porous hygroscopic material processed by this production process can obtain a multi-microporous hygroscopic material layer 1 composed of a microporous structure with extremely high density, and the multi-microporous hygroscopic material layer 1 can rapidly absorb moisture with a high capacity through the microporous surface 2 on the surface. The breathable layer 3, the high-resilience layer 4 or the breathable mesh frame 5, and the multi-microporous hygroscopic material layer 1 are connected and combined into a whole. According to the insole made of this material, when a user walks with feet, a repeatably-rebounded highly-breathable space is formed at the sole due to the high-resilience layer 4 or the breathable mesh frame 5 at the bottom, that is, the high-resilience sandwich mesh fabric, or a repeatably-rebounded highly-breathable space is formed at the insole by the mesh frame structure stacked by cube-shaped cage frames, air circulation airflow operates repeatedly, and moisture adsorbed in the multi-microporous hygroscopic material layer 1 and the breathable layer 3 is discharged and volatilized for drying, so that an automatically circulating comfortable space is formed inside a shoe.

[0066] The implementation provides a porous hygroscopic material, which is prepared by the porous hygroscopic material production process described above.

Claims

1. A porous hygroscopic material production process, comprising the following method steps:preparing a fabric soaking solution: in parts by weight, mixing and stirring 100 parts of water-insoluble polyurethane resin, 5-20 parts of diatomaceous earth, 20-50 parts of bleached wood powder, 10-120 parts of solvent, 2-5 parts of surfactant and hygroscopic and sweat releasing auxiliary agent for 30 minutes, and then performing vacuum stirring for defoaming;preparing a fabric coating solution: in parts by weight, mixing and stirring 100 parts of water-insoluble polyurethane resin, 5-20 parts of diatomaceous earth, 10-30 parts of bleached wood powder, 60-100 parts of solvent, 10-20 parts of colorant, 2-5 parts of surfactant and hygroscopic and sweat releasing auxiliary agent for 30 minutes, and then performing vacuum stirring for defoaming;immersing a carrier braided layer into the fabric soaking solution, with a ratio of a weight of the fabric soaking solution to an area of the carrier braided layer being 300-400 g / m2 to obtain a first bonding layer; using a pressure device to pressurize the first bonding layer for dewatering to remove 90% of water; applying the fabric coating solution onto a surface of the first bonding layer at a ratio of the weight of the fabric coating solution to the area of the first bonding layer of 300-500 g / m2 by scraping or coating, so as to obtain a second bonding layer; using a pressure device to pressurize the second bonding layer for dewatering to remove water;subjecting the second bonding layer to multi-stage water washing, then performing vacuum dehydration to remove water and residual solvent in the second bonding layer, and then conducting drying to obtain a multi-microporous hygroscopic material layer.

2. The porous hygroscopic material production process according to claim 1, further comprising a surface treatment step: subjecting one end surface of the multi-microporous hygroscopic material layer to surface frosting treatment.

3. The porous hygroscopic material production process according to claim 2, wherein a breathable layer is attached and connected to a surface of the multi-microporous hygroscopic material layer that is away from the end surface subjected to frosting treatment, and the breathable layer is any one of porous breathable PU foam, two-component in-mold foaming PU foam, EVA foam, and latex foam.

4. The porous hygroscopic material production process according to claim 3, further comprising a manufacturing step of a high-resilience layer:preparing an impregnation solution, which is water-soluble styrene butadiene rubber with a solid content of 31%;immersing a high-resilience mesh fabric in the impregnation solution, followed by heating, drying, and cross-linking, cooling to obtain the high-resilience layer, and attaching and connecting one end surface of the high-resilience layer to the other end surface of the breathable layer.

5. The porous hygroscopic material production process according to claim 3, further comprising a manufacturing step of a breathable mesh frame:using the other end surface of the breathable layer as a connecting surface to receive and connect with the breathable mesh frame printed by a 3D printer, wherein the breathable mesh frame is of a mesh frame structure formed by stacking cube-shaped cage frames connected by a plurality of supporting rods with a diameter of 1 mm and a length of 2 mm.

6. The porous hygroscopic material production process according to claim 1, further comprising a material recovery and treatment step: treating, recovering, and recycling coagulated and shed solid materials and drained and dehydrated wastewater liquid materials generated during the execution of the steps.

7. The porous hygroscopic material production process according to claim 1, wherein manufacturing steps of the carrier braided layer are as follows: performing napping and / or brushing on the carrier braided layer, then performing shearing, and then performing shaping in an environment at a temperature of 180° C. for 30 seconds;or, a raw material of the carrier braided layer is a spunlace non-woven fabric with a thickness of 0.4-0.5 mm.

8. The porous hygroscopic material production process according to claim 4, wherein both the fabric coating solution and the fabric coating solution have the diatomaceous earth with a fineness of 600 mesh and the bleached wood powder with a fineness of 400-600 mesh; prior to the step of using the pressure device to pressurize the first bonding layer for dewatering to remove 90% of the water, placing the first bonding layer in a coagulation tank with a water temperature of 40-50° C. for 20 seconds; a water washing duration of multi-stage water washing for the second bonding layer is 3-5 minutes; a drying temperature before obtaining the multi-microporous hygroscopic material layer is 160° C.; the high-resilience mesh fabric is a sandwich mesh fabric with a weight of 400 g / m2 and an upper-lower layer gap of not less than 4 mm; an impregnation amount of the sandwich mesh fabric with the impregnation solution is 50 g in dry weight, and a subsequent heating and drying temperature is 150° C.

9. A porous hygroscopic material, wherein the porous hygroscopic material is prepared by the porous hygroscopic material production process according to claim 1.

10. A porous hygroscopic insole, comprising the porous hygroscopic material according to claim 9, and the porous hygroscopic material is cut using a hot-pressing mold or a cold-pressing mold to form an insole.

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