Flex-resistant laminate, shoe sole, shoe, and laminate manufacturing method
By combining carbon fiber layers and basalt fiber layers on both sides of the intermediate layer and adjusting the laying angle and layer ratio, a multi-layer fiber structure is formed, which solves the problem of stiffness reduction and brittle fracture of traditional carbon fiber laminates after long-term use, and achieves improved bending resistance and structural stability.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- XTEPCHINA
- Filing Date
- 2025-10-13
- Publication Date
- 2026-07-09
AI Technical Summary
Traditional carbon fiber laminates for footwear exhibit significant stiffness reduction after prolonged use, are not resistant to bending, have low elongation, and are prone to brittle fracture, leading to structural failure.
Carbon fiber layers are composited on both sides of the intermediate layer group. The basalt fiber layer is laid at an angle of 0 or 90°. The ratio of carbon fiber layer to basalt fiber layer is 1:1-3. They are bonded together by resin adhesive. The layup angles are 25°, -25°, 0, 90°, 0, 90°, 25° and -25°, forming a multi-layer fiber structure.
It improves the bending resistance of laminates, slows down the stiffness decay after multiple bends, increases elongation, avoids brittle fracture, and makes the structure less prone to failure.
Smart Images
Figure CN2025127199_09072026_PF_FP_ABST
Abstract
Description
A method for manufacturing a flexurally resistant laminate, a shoe sole, a shoe, and the laminate. Technical Field
[0001] This invention relates to a shoe material and its manufacturing method, particularly a flexural laminate, a shoe sole, a shoe, and a method for manufacturing the laminate. Background Technology
[0002] Carbon fiber laminates (also known as carbon plates) are increasingly used in athletic shoes, especially in marathon running shoes and professional competitive basketball shoes. Applying carbon fiber laminates to athletic shoes can effectively improve their support performance, provide better energy return, and thus enhance various athletic performance metrics.
[0003] Traditional carbon fiber laminates for footwear are typically formed by simply laying down carbon fiber prepreg. Technical issues
[0004] While traditional carbon fiber laminates for footwear can provide good rigidity to finished shoes in the early stages of use, their rigidity decreases significantly after repeated bending over a long period of time. They are not resistant to bending and affect the product experience. In addition, these carbon fiber laminates have low elongation and are prone to brittle fracture. They are easily broken by high-frequency running, jumping and bending at large angles, which can lead to structural failure. Technical solutions
[0005] The purpose of this invention is to provide a flexurally resistant laminate, shoe sole, shoe, and a method for manufacturing the laminate that is resistant to bending and whose structure is not prone to failure.
[0006] To achieve the above objectives, the present invention provides the following technical solution:
[0007] A flexurally resistant laminate includes an intermediate layer assembly and carbon fiber layers respectively bonded to both sides of the intermediate layer assembly;
[0008] The intermediate layer group includes a basalt fiber layer, and the basalt fiber layer is laid at an angle of 0 or 90°; or
[0009] The intermediate layer group comprises at least two sequentially stacked basalt fiber layers, with adjacent basalt fiber layers laid at angles of 0° and 90°, respectively, and the lay-up angles of adjacent basalt fiber layers are not the same; or
[0010] The intermediate layer group includes two basalt fiber layers and a carbon fiber layer located between the two basalt fiber layers. The layup angle of the two basalt fiber layers is 90°, and the layup angle of the carbon fiber layer located between the two basalt fiber layers is 0°.
[0011] As an improvement of the present invention, the ratio of the number of carbon fiber layers to the number of basalt fiber layers is 1:1-3.
[0012] As an improvement of the present invention, each of the basalt fiber layers and each of the carbon fiber layers are lay-ups, and there are eight lay-ups. The lay-up angles of each lay-up from bottom to top are 25°, -25°, 0, 90°, 0, 90°, 25° and -25°.
[0013] As an improvement of the present invention, adjacent two layers are bonded together by resin adhesive, and each layer is a multi-layer fiber structure.
[0014] A shoe sole includes a midsole, wherein the inner or outer surface of the midsole is laminated with the aforementioned flexural laminate.
[0015] A shoe includes a sole and an upper that are fixedly connected to each other, wherein the sole is made using the aforementioned sole design.
[0016] A method for manufacturing a flexurally resistant laminate includes the following steps:
[0017] S1. Lamination: Carbon fiber prepreg and basalt fiber prepreg are used for layup to obtain composite material;
[0018] S2. Molding: The composite material is placed in a hot pressing mold and subjected to hot pressing, heat preservation and cooling curing in sequence to obtain the flexurally resistant laminate as described in any one of claims 1-4.
[0019] As an improvement of the present invention, in step S2, before placing the composite material into the hot press molding die, the composite material is cut according to the cavity shape of the hot press molding die.
[0020] As an improvement of the present invention, in step S2, after the composite material is cooled and cured, it is further subjected to grinding, cleaning, sandblasting and / or painting.
[0021] As an improvement of the present invention, in step S2, the temperature of the hot pressing treatment is 110-220℃, the pressure is 1-3MPa, and the time of the heat preservation treatment is 5-30min. Beneficial effects
[0022] By adopting the above technical solution, the present invention has the following beneficial effects:
[0023] By compositing carbon fiber layers on both sides of the intermediate layer, which is mainly composed of basalt fiber layers, and limiting the laying angle of the basalt fiber layers in the intermediate layer, the stiffness decay after multiple bends can be slowed down, the bending resistance can be improved, and the elongation of the laminate can be increased, avoiding brittle fracture and making the structure less prone to failure. Attached Figure Description
[0024] Figure 1 is a schematic diagram of the structure of the laminate in Example 1;
[0025] Figure 2 is a schematic diagram of the structure of the laminate in Example 7.
[0026] The corresponding labels in the image are as follows:
[0027] 10-Carbon fiber layer; 20-Basalt fiber layer. Embodiments of the present invention
[0028] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.
[0029] This invention provides a composite fiber laminate and a flexural laminate. The two have different structures but the main manufacturing processes are the same and their performance is similar. Both have good bending resistance and a large bending angle. They are not prone to bending fracture under high-frequency running and jumping and large-angle bending, and have good structural stability.
[0030] The embodiments 1-7 provided by the present invention are all composite fiber laminates, including a surface layer group and a base layer group that are bonded to each other. The surface layer group includes at least two basalt fiber layers stacked sequentially from top to bottom, and the base layer group includes at least one carbon fiber layer. The ratio of the number of carbon fiber layers to the number of basalt fiber layers is 1:1-7 or 3:1.
[0031] Embodiments 7-10 of the present invention are all flexurally resistant laminates, comprising an intermediate layer assembly and carbon fiber layers respectively bonded to both sides of the intermediate layer assembly; wherein, the intermediate layer includes at least one basalt fiber layer, and the basalt fiber layer is laid at an angle of 0 or 90°. The preferred layer ratio of carbon fiber layer to basalt fiber layer is 1:1-3.
[0032] For ease of description, each carbon fiber layer 10 and each basalt fiber layer 20 are referred to as a layup. In this invention, the layup angle of each fiber layer refers to the angle between the fiber extension direction of the corresponding fiber layer and the reference direction, with clockwise direction as positive. The reference direction is a direction preset during production and can be any direction. Preferably, in each embodiment of this invention, there are eight layups, and the layup angles of each layup are 25°, -25°, 0, 90°, 0, 90°, 25° and -25° from bottom to top.
[0033] Preferably, adjacent layers are bonded together by a resin adhesive, the resin grade being WP-S5001, and each layer is a multi-layer fiber structure.
[0034] The structure and layering of each embodiment will be described below.
[0035] Example 1
[0036] As shown in Figure 1, the surface layer of the composite fiber laminate provided in this embodiment includes two basalt fiber layers 20 stacked on each other, and the base layer includes six carbon fiber layers 10 stacked sequentially. The specific number of layers (arranged in order from top to bottom), laying angle and layup materials are shown in the table below.
[0037]
[0038] Example 2
[0039] The composite fiber laminate provided in this embodiment has two sets of surface layers and a base layer set located between the two sets of surface layers. The surface layer set includes two basalt fiber layers stacked on top of each other, and the base layer set includes four carbon fiber layers stacked in sequence. The specific number of layers (the number of layers is arranged in order from top to bottom), laying angle and layup materials are shown in the table below.
[0040]
[0041] Example 3
[0042] The composite fiber laminate provided in this embodiment is essentially a flexural laminate. It has two face layer groups and a base layer group located between the two face layer groups. The upper face layer group includes two basalt fiber layers stacked on top of each other, and the lower face layer group includes three basalt fiber layers stacked on top of each other. The base layer group includes one basalt fiber layer and carbon fiber layers respectively attached to both sides of the basalt fiber layer. The specific number of layers (arranged in order from top to bottom), laying angle and layup materials are shown in the table below.
[0043]
[0044] Example 4
[0045] The composite fiber laminate provided in this embodiment is essentially a flexurally resistant laminate. It has two face layers and a base layer between them. The lower face layer consists of two stacked basalt fiber layers, while the upper face layer consists of three stacked basalt fiber layers. The base layer (also called the intermediate layer) consists of one basalt fiber layer and carbon fiber layers bonded to both sides of the basalt fiber layer. The intermediate layer consists of one basalt fiber layer, and the layup angle of this basalt fiber layer can be 0° or 90°. In this embodiment, the layup angle is 0°. The specific number of layers (arranged from top to bottom), layup angle, and layup materials are shown in the table below.
[0046]
[0047] Example 5
[0048] The composite fiber laminate provided in this embodiment has two sets of surface layers and a base layer set located between the two sets of surface layers. The upper surface layer set includes five layers of basalt fiber stacked sequentially, and the lower surface layer set includes two layers of basalt fiber stacked sequentially. The base layer set includes one carbon fiber layer. The specific number of layers (arranged in order from top to bottom), laying angle, and layup materials are shown in the table below.
[0049]
[0050] Example 6
[0051] The composite fiber laminate provided in this embodiment has two surface layer groups and a base layer group located between the two surface layer groups. The upper surface layer group includes three basalt fiber layers stacked sequentially, and the lower surface layer group includes four basalt fiber layers stacked sequentially. The base layer group includes one carbon fiber layer. The specific number of layers (arranged in order from top to bottom), laying angle, and layup materials are shown in the table below.
[0052]
[0053] Example 7
[0054] As shown in Figure 2, the flexural laminate provided in this embodiment includes an intermediate layer comprising two or more sequentially stacked basalt fiber layers 20. The layup angles of two adjacent basalt fiber layers 20 are 0° and 90°, respectively, and the layup angles of two adjacent basalt fiber layers 20 are different from each other. In this embodiment, the intermediate layer comprising four sequentially stacked basalt fiber layers 20 is used as an example for illustration. Two sequentially stacked carbon fiber layers 10 are adhered to both the upper and lower sides of the intermediate layer. The specific number of layers (arranged in top-to-bottom order), layup angles, and layup materials are shown in the table below.
[0055]
[0056] Example 8
[0057] The difference between the flexural laminate provided in this embodiment and that in Embodiment 1 is that the carbon fiber layers of the 5th and 6th lay-ups in Embodiment 1 are replaced with basalt fiber layers, so that the 5th and 6th lay-ups form an intermediate layer. The specific number of lay-ups (arranged in order from top to bottom), lay-up angle and lay-up materials are shown in the table below.
[0058]
[0059] Example 9
[0060] The difference between the flexural laminate provided in this embodiment and that in embodiment 4 is that the basalt fiber layers in the 7th and 8th layups in embodiment 4 are replaced with carbon fiber layers. The specific number of layups (arranged in order from top to bottom), layup angle, and layup materials are shown in the table below.
[0061]
[0062] Example 10
[0063] The flexural laminate provided in this embodiment is essentially a composite fiber laminate. Its intermediate layer comprises two basalt fiber layers and a carbon fiber layer located between the two basalt fiber layers. The layup angle of the two basalt fiber layers is 90°, and the layup angle of the carbon fiber layer between the two basalt fiber layers is 0°. A carbon fiber layer is adhered to the upper side of the intermediate layer, and a top layer is adhered to the upper side of this carbon fiber layer. This top layer comprises two mutually bonded basalt fiber layers. Two carbon fiber layers are sequentially bonded to the lower side of the intermediate layer. The specific number of layers (arranged from top to bottom), layup angle, and layup materials are shown in the table below.
[0064]
[0065] The present invention also provides a carbon fiber laminate made solely of carbon fiber prepreg and a basalt fiber laminate made solely of basalt fiber prepreg as comparative examples. The specific number of layers (arranged in descending order), layup angle, and layup materials are as follows:
[0066] Comparative Example 1
[0067]
[0068] Comparative Example 2
[0069]
[0070] Example 11
[0071] This embodiment provides a shoe sole, including a midsole, wherein the inner or outer surface of the midsole is laminated with a composite fiber laminate, a flexural laminate, a carbon fiber laminate, or a basalt fiber laminate, wherein the laminate is any of the laminates provided in Embodiments 1-10 and Comparative Examples 1-2.
[0072] The specific composite method is the same as that of conventional carbon fiber plate soles, and is not the focus of this embodiment, so it will not be described in detail here. The layup reference direction of the carbon fiber laminate is the same as the length direction of the sole.
[0073] Example 12
[0074] This embodiment provides a finished shoe, including a sole and an upper that are fixedly connected to each other, and the sole adopts the sole provided in Embodiment 11.
[0075] Example 13
[0076] This embodiment provides a method for manufacturing a composite fiber laminate or a flexurally resistant laminate, used to obtain the laminates in Examples 1-10, which includes the following steps:
[0077] S1. Lay-up: Carbon fiber prepreg and basalt fiber prepreg are laid up according to the desired number of layers, angles and material requirements of the laminate to obtain a composite material. The specific lay-up process is the same as the conventional laminate lay-up process and is not the focus of this embodiment, so it will not be described in detail here.
[0078] The fiber grades used in carbon fiber prepregs are T400, T700, T100 or T1100; the basalt fiber grade is BF825K.
[0079] S2. Molding: The composite material is cut according to the cavity shape of the hot press molding die. The cavity shape can be set according to the actual product needs, such as the shape of a carbon fiber plate for shoes or an insole. Then, the cut composite material is placed in the hot press molding die for hot pressing, heat preservation, and cooling curing. If necessary, grinding, cleaning, sandblasting, and / or painting can be performed after cooling curing to obtain carbon fiber laminate. The above processes are all conventional processes and will not be described in detail here. Preferably, the curing temperature is 110-220℃, the pressure is 1-3MPa, and the molding time is 5-30min.
[0080] Preferably, in step S2, after the cutting is completed, the cut composite material is pre-shaped using a pressure shaping device, and then placed into a pressure forming mold for processing. This helps to improve the molding efficiency and reduce the internal stress of the material.
[0081] The difference between the comparative laminate manufacturing method provided by the present invention and the laminates of the above embodiments is that only carbon fiber prepreg and basalt fiber prepreg are used during the layup.
[0082] Initial tear force and initial tear displacement tests were conducted on the laminates of Examples 1-10 and Comparative Examples 1-2, respectively. Simultaneously, initial stiffness tests and stiffness tests after 200,000 flexural cycles were performed on finished shoes made using the laminates of Examples 1-10 and Comparative Examples 1-2 (the stiffness test method and standard for finished shoes refer to GB / T 32023-2023 "Test Methods for Whole Footwear - Stiffness of Flexural Parts"). The following test data were obtained:
[0083]
[0084] In the table above, the sample size refers to the size of the finished shoe being tested, and the maximum number of bends refers to the number of bends required when the stiffness of the finished shoe after bending is less than or equal to 60% of its initial stiffness. Generally speaking, the larger the initial fracture displacement of the laminate, the larger the bendable angle. In the above test, a three-point bending test was used, with a fixed span of 46mm. The bendable angle was obtained by taking the inverse trigonometric function of the initial fracture displacement of the laminate.
[0085] The test results show that, compared to simple carbon fiber laminates, the laminates provided in each embodiment exhibit significant improvements in initial tear displacement, bending angle, finished shoe stiffness, maximum number of bends, and finished shoe stiffness after 200,000 bends. Compared to simple basalt fiber laminates, the laminates provided in each embodiment also show significant improvements in initial tear force. Under the premise of ensuring a certain amount of breaking force, a larger breaking displacement or a larger bending angle indicates that the component is less prone to bending fracture. Therefore, the soles made using the laminates provided in this embodiment are less prone to bending fracture under high-frequency running, jumping, and large-angle bending.
[0086] The present invention has been described in detail above with reference to the accompanying drawings. However, the embodiments of the present invention are not limited to the above embodiments. Those skilled in the art can make various modifications to the present invention based on the prior art, and these modifications all fall within the protection scope of the present invention.
Claims
1. A flexurally resistant laminate, characterized in that, It includes an intermediate layer assembly and carbon fiber layers respectively bonded to both sides of the intermediate layer assembly; The intermediate layer group includes a basalt fiber layer, and the basalt fiber layer is laid at an angle of 0 or 90°; or The intermediate layer group comprises at least two sequentially stacked basalt fiber layers, with adjacent basalt fiber layers laid at angles of 0° and 90° respectively, and the lay-up angles of adjacent basalt fiber layers are not the same; or The intermediate layer group includes two basalt fiber layers and a carbon fiber layer located between the two basalt fiber layers. The layup angle of the two basalt fiber layers is 90°, and the layup angle of the carbon fiber layer located between the two basalt fiber layers is 0°.
2. The flexurally resistant laminate as described in claim 1, characterized in that, The ratio of the number of carbon fiber layers to the number of basalt fiber layers is 1:1-3.
3. The flexurally resistant laminate as described in claim 1, characterized in that, Each of the basalt fiber layers and each of the carbon fiber layers are plies, and there are eight plies. The layup angles of each ply from bottom to top are 25°, -25°, 0°, 90°, 0°, 90°, 25° and -25°.
4. The flexurally resistant laminate as described in claim 3, characterized in that, The adjacent two layers are bonded together by resin adhesive, and each layer is a multi-layer fiber structure.
5. A shoe sole, comprising a midsole, characterized in that, The inner or outer surface of the midsole is composited with the flexural laminate as described in any one of claims 1-4.
6. A shoe comprising a sole and an upper fixedly connected to each other, characterized in that, The sole is the sole as described in claim 5.
7. A method for manufacturing a flexurally resistant laminate, characterized in that, Includes the following steps: S1. Lamination: Carbon fiber prepreg and basalt fiber prepreg are used for layup to obtain composite material; S2. Molding: The composite material is placed in a hot pressing mold and subjected to hot pressing, heat preservation and cooling curing in sequence to obtain the flexurally resistant laminate as described in any one of claims 1-4.
8. The method for manufacturing the flexurally resistant laminate as described in claim 7, characterized in that, In step S2, before placing the composite material into the hot press molding die, the composite material is cut according to the cavity shape of the hot press molding die.
9. The method for manufacturing the flexurally resistant laminate as described in claim 7, characterized in that, In step S2, after the composite material is cooled and cured, it is also subjected to grinding, cleaning, sandblasting and / or painting.
10. The method for manufacturing the flexurally resistant laminate as described in claim 7, characterized in that, In step S2, the temperature of the hot pressing treatment is 110-220℃, the pressure is 1-3MPa, and the heat preservation treatment time is 5-30min.