Patent ID: 12239187

DETAILED DESCRIPTION OF THE INVENTION

The applicant first explains here, the following is a detailed description of the technical content and features of the invention based on several preferred embodiments listed in conjunction with the drawings. The directional adjectives such as “top, bottom, up, down, inside, outside” mentioned in the content of this manual are only exemplary descriptive terms based on the normal direction of use, and are not intended to limit the scope of claims. Secondly, in the embodiments and drawings that will be introduced below, the same element numbers represent the same or similar elements or their structural features.

Please refer toFIG.1,FIG.2andFIG.9, which are the first embodiment of the shoe insole processing method of the present invention. The shoe insole processing method comprises the steps of: step a) attaching foams16to a bottom surface122of an upper insole layer12, corresponding to the heel portion42, the inner arch portion32a, and the metatarsal portion22of the structure of the human foot, step b) attaching a lower insole layer14to the bottom surface122of the upper insole layer12, and step c) perform cold pressing forming.

In detail, the insole1processing method provided by the first embodiment of the present invention includes an insole body10. First, take a foamed substrate as the upper insole layer12of the insole body10. The foamed substrate is a breathable and elastic material such as ethylene-vinyl acetate copolymer (EVA) as an example. First, apply a layer of glue to the bottom surface122of the unprocessed upper insole layer12. While it is drying, cut foams16and an elongated foams16a, and cut a gap161between each foam16and the respective elongated foams16a, and the gap161defines an air cavity162. After attaching the foams16with the air cavity162to the positions corresponding to the heel portion42, the inner arch portion32a, and the metatarsal portion22, attach the elongated foams16abetween the foams16corresponding to the metatarsal portion22and the heel portion42, the foams16corresponding to the metatarsal portion22and of the inner arch portion32a, and the foams16corresponding to the inner arch portion32aand the heel portion42. It is also possible to attach two foams16in parallel to the groove12aand the concave runner12bto form the gap161. Then, attach the lower insole layer14to the bottom surface122of the upper insole layer12. After the semi-finished product of the insole body10is prepared, it is heated in an oven, and the heating temperature is controlled at 120-160° C. After the semi-finished product is softened, it is cold-pressed and shaped. The molding time is 50-70 seconds, and the pressure is set at about 40-55 kg/cm2. After shape forming, cut to make the insole1.

After the insole1processed by the insole1processing method provided by the first embodiment is taken out from the cold pressing mold, the insole1is forced to bulge outward by the foams16and the elongated foams16abetween the upper insole layer12and the lower insole layer14, forming bulges18and air flow channels19.

Please refer toFIGS.3-5, which are the second embodiment of the shoe insole processing method of the present invention. The shoe insole processing method comprises the steps of: step a) perform cold pressing forming on a foamed substrate to form an upper insole layer12with a groove12aand a concave runner12b, step b) after attaching foams16to the groove12a, attach a lower insole layer14to the bottom surface122of the upper insole layer12, and step c) heating and cold pressing forming, cutting to make insole1. Specifically, a first mold (not shown in the drawings) is used to fill a foamed substrate into the first mold (not shown in the drawings), and the mold is closed and cold pressed to obtain the upper insole layer12. During cold pressing forming, bulges18and air flow channels19are formed in the upper insole layer12corresponding to the heel portion42, inner arch portion32a, and metatarsal portion22of the sole structure subject to the shape of the first mold, as shown inFIG.5. Wherein, each bulge18integrally protrudes toward the top surface121of the upper insole layer12to form a first convex surface121a, and a first concave surface121bdented on the bottom surface122of the upper insole layer12corresponding to the first convex surface121a. The first concave surface121bdefines a groove12a. The concave runner12bis connected between each of the bulges18to form an air flow channel19(described in the embodiment of the insole structure below), that is, the first cold pressing process is completed. Then remove the upper insole layer12from the mold. It should be noted that the depth of bulges18of cold pressing is slightly deeper than that of air flow channel19. Next, cut foams16and elongated foams16awith air cavity162, and paste them into the groove12aand the concave runner12b. At the same time, take another foamed substrate as the lower insole layer14of the insole1, and glue the bottom surface122of the upper insole layer12with the foams16and the bonding surface141of the lower insole layer14respectively. After drying, the upper insole layer12and the lower insole layer14are bonded to each other to make the foams16located between the upper insole layer12and the lower insole layer14. It should be noted that the foams16in the groove12aand the elongated foams16ain concave runner12bcan be connected to each other or separate foams16.

Put the laminated upper insole layer12, lower insole layer14and foams16into an oven for heating. The heating temperature is controlled at 120-160° C. to soften the upper insole layer12and the lower insole layer14to obtain the semi-finished product of insole body10. At this time, the foams16are located between the groove12aof the upper insole layer12and the lower insole layer14, forming bulges18, and the elongated foams16aare located between the concave runner12band the lower insole layer14, forming an air flow channel19. In addition, when the semi-finished product of the insole body10is still in a high temperature state, a breathable fabric13is attached to the top surface121of the upper insole layer12and used as the upper in contact with the sole of the foot.

Next, perform secondary cold pressing forming on insole body10. The second mold of the secondary cold pressing forming is made by 1:1 according to the specifications of the last. The second mold has mold cavities located at positions corresponding to the bulges18and air flow channel19of the upper insole layer12, and the module corresponding to the lower insole layer14does not have any mold cavity. Fill the semi-finished product of the softened insole body10into the second mold, so that the bulges18and air flow channel19of the upper insole layer12are placed in the mold cavities. After the mold is closed, cold pressing forming is performed at a temperature below 30° C., the molding time is 50 to 70 seconds, and the pressure is set at about 40 to 55 kg/cm2. Open the mold and take out the insole body10, and use a cutting knife to cut the contour of the insole body10to obtain the insole1. The insole body10after high-pressure sealing and molding, due to the push of the foams16in the groove12aand the convex runner12b, the lower insole layer14is forced to bulge outward at the positions corresponding to bulges18and air flow channel19of the upper insole layer12. When the air in the insole body10is subjected to high pressure processing in the second mold, it is forced to be discharged into the air cavities162of the foams16, so that the air cavities162is filled with air.

What needs to be explained is that the manufacturer can optionally add foams16to the groove12aand the concave runner12bafter forming the upper insole layer12, or directly bond the lower insole layer14to the bottom surface122of the upper insole layer12that is provided with the groove12aand the concave runner12b, so that air is filled between the groove12aof the upper insole layer12and the lower insole layer14, and between the concave runner12band the lower insole layer14, forming bulges18that can be deformed between the compressed state and the diastolic state. In this way, when the user is stepping on, the bulges18can generate air circulation through the air flow channel19.

Below, the insole1structure processed by the insole1processing method provided by the first or second embodiment of the present invention will be further explained. Please refer toFIGS.4to9, which are the first embodiment of the insole1of the present invention. The insole1comprises an insole body10. The insole body10comprises an upper insole layer12and a lower insole layer14, the top surface121of the upper insole layer12is in contact with the sole of the foot, and the bottom surface122of the upper insole layer12is bonded to the lower insole layer14through cold pressing forming. The material of upper insole layer12and the lower insole layer14is a breathable and elastic foam material such as ethylene-vinyl acetate copolymer (EVA) as an example.

The insole body10of the first embodiment comprises a forefoot area20, a midfoot area30, and a hindfoot area40. The hindfoot area40comprises a heel portion42, corresponding to the calcaneus of the human foot. The forefoot area20comprises an inner metatarsal portion22a, an outer metatarsal portion22b, an inner toe portion23a, and an outer toe portion23b. The inner metatarsal portion22acorresponds to the first metatarsal of the human foot. The outer metatarsal portion22bcorresponds to the second, third, fourth and fifth metatarsals of the human foot. The inner toe portion23acorresponds to the first phalanx of the human foot. The outer toe portion23bcorresponds to the second, third, fourth and fifth phalanx of the human foot. The midfoot area30is located between the forefoot area20and the hindfoot area40. The midfoot area30comprises an inner arch portion32aand an outer arch portion32b.

The bulges18of the upper insole layer12of the insole body10of the first embodiment further comprises a first bulge18a, a second bulge18b, and a third bulge18c. The first bulge18ais formed in the inner metatarsal portion22aand outer metatarsal portion22bof the forefoot area20. The second bulge18bis formed in the inner arch portion32aof the midfoot area30. The third bulge18cis formed in the heel portion42of the hindfoot area40. The area of the top surface121of the upper insole layer12covering the bulges18bulges outward to form a first convex surface121a. The area of the bottom surface122of the upper insole layer12covering the bulges18dents to form a first concave surface121b. The first concave surface121bdefines a groove12afor attaching a foam16. The foam16can be memory foam or other foam16with good resilience, support and shock absorption function. The foam16has a gap161, which defines an air cavity162. In addition, connect an air flow channel19between each of the first, second and third bulges18a,18b, and18c. The area of the top surface121of the upper insole layer12covering the air flow channel19is integrally convex outward to form a second convex surface121c. The area of the bottom surface122of the upper insole layer12covering the air flow channel19and corresponding to the second convex surface121cis integrally recessed to form a second inner concave surface121d. The second inner concave surface121ddefines a concave runner12b. There is a foam16inside each concave runner12b. The air flow channel19comprises a first air flow channel19a, a second air flow channel19band a third air flow channel19c. In detail, one end of the first air flow channel19ais connected to the first bulge18aat the position of the outer metatarsal portion22b, and the other end of the first air flow channel19ais connected to the third bulge18c. One end of the second air flow channel19bis connected to the first bulge18aat the position of the inner metatarsal portion22a, and the other end of the second air flow channel19bis connected to the second bulge18b. One end of the third air flow channel19cis connected to the second bulge18b, and the other end of the third air flow channel19cis connected to the third bulge18c. The first air flow channel19afurther comprises an extension section191, connecting the first air flow channel19aand the second bulge18b. It is worth mentioning that the depth of the groove12ais deeper than that of the concave runner12b.

The lower insole layer14is attached to the bottom surface122of the upper insole layer12, so that the foams16are located between the groove12aand the lower insole layer14of the upper insole layer12, and between the convex runner12band the lower insole layer14. When the upper insole layer12and the lower insole layer14are shape formed by high pressure sealing, the lower insole layer14corresponding to the first bulge18a, second bulge18band third bulge18cof the upper insole layer12is forced by the foam16in the groove12ato bulge outward, and the lower insole layer14corresponding to the first air flow channel19a, second air flow channel19band third air flow channel19cof the upper insole layer12is forced by the foam16in the concave runner12bto bulge outward, so that the foams16are fixedly attached to the inside of the first bulge18a, the second bulge18b, the third bulge18c, the first air flow channel19a, the second air flow channel19band the third air flow channel19c. The air cavity162in each foam16is filled with air, so that the foams16can be deformed between the compressed state and the diastolic state. It is worth mentioning that the thickness of the third bulge18clocated in the heel portion42is thicker than the thickness of the first bulge18alocated in the inner metatarsal portion22aand the outer metatarsal portion22b, and the thickness of the upper insole layer12is thinner than the thickness of the lower insole layer14.

In actual use of the insole1of the first embodiment, when the heel portion42of the insole body10is stressed, the foam16in the third bulge18cwill be squashed to a compressed state, so that the air in the air cavity162of the foam16is squeezed out of the third bulge18cand passes through the first air flow channel19aand the third air flow channel19cinto the air cavities162of the foams16in the first bulge18aand the second bulge18b, making the first bulge18aand second bulge18bform a diastolic state. Conversely, when the inner metatarsal portion22aand the outer metatarsal portion22bare stressed, the foam16in the first bulge18awill be squeezed to a compressed state, so that the air in the air cavity162of the foam16is squeezed out of the first bulge18aand passes through the first air flow channel19aand the second air flow channel19binto the air cavities162of the foams16in the second bulge18band the third bulge18c, making the second bulge18band the third bulge18cform a diastolic state.

In this way, when the soles of the feet step on and off the ground repeatedly, through the support of the foams16and the air convection of the air cavities162, the insole1of the present invention can easily restore the bulges18and the air flow channel19to a raised state, avoiding the insole1from being crushed by the weight of the human body after a long time of use.

In addition, the air cavity162of the foam16located in the second bulge18bat the inner arch portion32aperforms air convection with the air cavities162in the first bulge18aand the third bulge18c, so that the foam16form a diastolic state to provide support for the inner arch portion32a, reducing the internal rotation of the foot. The high resilience foams16have an appropriate pressure release speed, and provide appropriate cushioning for the stress points on the bottom of the foot, such as the heel portion, the arch of the foot and the metatarsal portion, so that the bottom of the foot and the insole1are more compliant.

Please refer toFIG.10, which is the insole1provided by the second embodiment of the present invention, in which the material, distinguishing parts and components of the insole body10are exactly the same as those of the aforementioned first embodiment, so the applicant will not repeat them, but only the differences from the aforementioned first embodiment are explained.

In the second embodiment of the present invention, the bulges18of the upper insole layer12of the insole body10further comprises a fourth bulge18d, a fifth bulge18e, a sixth bulge18f, a seventh bulge18g, an eighth bulge18h, a ninth bulge18iand a tenth bulge18j. The fourth bulge18dis formed in the inner toe portion23aof the forefoot area20. The fifth bulge18eis formed in the outer toe portion23bof the forefoot area20. The sixth bulge18fis formed in the inner metatarsal portion22aof the forefoot area20. The seventh bulge18gis formed in the outer metatarsal portion22bof the forefoot area20. The eighth bulge18his formed in the inner arch portion32aof the midfoot area30. The ninth bulge18is formed in the outer arch portion32bof the midfoot area30. The tenth bulge18jis formed in the heel portion42of the hindfoot area40. In addition, the air flow channel19of this embodiment further comprises a second air flow channel19b, a fourth air flow channel19d, a fifth air flow channel19e, a sixth air flow channel19f, a seventh air flow channel19g, an eighth air flow channel19hand a ninth air flow channel19i. The second air flow channel19bconnects the sixth bulge18fand the eighth bulge18h. The fourth air flow channel19dconnects the ninth bulge18iand the tenth bulge18j. The fifth air flow channel19econnects the seventh bulge18gand the ninth bulge18i. The sixth air flow channel19fconnects the fifth bulge18eand the seventh bulge18g. The seventh air flow channel19gconnects the fourth bulge18dand the sixth bulge18fThe eighth air flow channel19hconnects the eighth bulge18hand the ninth bulge18i. The ninth air flow channel19iconnects the fifth bulge18eand the sixth bulge18f.

In actual use of the insole1of the second embodiment, in addition to having the fourth-tenth bulges (18d-18j) as described in the first embodiment, the support of foams16and the air convection of the air cavities162make each bulge18and the air flow channel19are easy to recover to the bulge state, a bulge18is added to each of the inner toe portion23a, outer toe portion23band outer arch portion32bto make the bottom of the sole of the foot evenly stressed and increase the comfort of the foot.

Please refer toFIG.11, the insole body10of the insole1provided by the third embodiment of the present invention mainly comprises a plurality of bulges18and a plurality of air flow channels19connected to the bulges18. The material, distinguished parts and components of the insole1of this third embodiment are slightly the same as the first embodiment, and the differences are outlined hereinafter:

The forefoot area20of the insole body10of the third embodiment of the present invention comprises a first circular path24, the midfoot area30comprises a second circular path34, and the hindfoot area40comprises a third circular path44. The forefoot area20of the insole body10of this embodiment comprises a plurality of bulges18, which are arranged along the first circular path24. In addition, the air flow channel19also comprises a plurality of eleventh air flow channels19j. These eleventh air flow channels19jare located in the first circular path24, connecting the bulges18of the forefoot area20. Similarly, midfoot area30also comprises a plurality of bulges18arranged along the second circular path34. The midfoot area30also comprises a plurality of twelfth air flow channels19k, and the twelfth air flow channels19kconnect the bulges18of the midfoot area30. In addition, the hindfoot area40further comprises a plurality of bulges18arranged along the third circular path44, and a plurality of thirteenth air flow channels19mconnecting the bulges18of the hindfoot area40.

It should be noted that the number and size of the bulges18of the insole1of the third embodiment in the forefoot area20, midfoot area30and hindfoot area40are not limited to the arrangement shown inFIG.11, and it simply needs to arrange the bulges18along the first, second and third circular paths24,34,44.

Please refer toFIG.12, which shows the insole body10of the insole1provided by the fourth embodiment of the present invention. The material, distinguished parts and components of the insole body10of this fourth embodiment are slightly the same as the third embodiment, and the differences are outlined hereinafter:

In this fourth embodiment, in addition to that the forefoot area20, midfoot area30and hindfoot area40of the upper insole layer12of the insole body10have bulges18arranged along the first, second and third circular paths24,34,44as the arrangement of the third embodiment, a plurality of bulges18are vertically arranged between the first, second and third circular paths24,34,44. And each of the forefoot area20, midfoot area30and hindfoot area40comprises a plurality of fourteenth air flow channels19nand a plurality of fifteenth air flow channels19o. The fourteenth air flow channels19nconnect the bulges18that are vertically arranged in the first circular path24, and also connect the bulges18arranged vertically in the first circular path24and the bulges18located on the first circular path24. In addition, the fifteenth air flow channels190connect the bulges18that are vertically arranged in the second circular path34, and also connect the bulges18arranged vertically in the second circular path34and the bulges18located on the second circular path34.

In summary, in the insole1processing method of the present invention, according to the properties of the insole substrate, such as density, heat resistance, etc., you can optionally paste foams16between the unprocessed upper and lower insole layers12,14, and directly put the semi-finished product of the assembled insole body10through cold pressing. Alternatively, you can cold press the upper insole layer12first, so that the upper insole layer12has a groove12aand a concave runner12bthat can accommodate foams16, then attach the foams16, and then perform secondary cold pressing to obtain an insole1, which can effectively simplify the process. In addition to not having to consider the heat-resistant requirements of the mold material, the industry can apply appropriate processing procedures according to the nature of the insole1substrate to improve production efficiency. The insole1provided by the present invention is provided with breathable and high resilience foams16at the stress points of the sole of the foot such as heel portion42, inner arch portion32aand metatarsal portion22. With the air flow channel19and the air cavity162, the foams16can be deformed between the diastolic state and the compressed state, so that the insole body10can completely fit the foot shape. It solves the problem of deformation and collapse of the conventional insole after a long time of use, and reduces the foot pain caused by standing or walking for a long time.