TW202434434A - Recycled carbon fiber arch insole with recycled carbon fiber underlay - Google Patents

Abstract

In order to solve the problems of traditional arch insoles, such as being too thick and poor in usability, being not environmentally friendly, and the current carbon fiber materials for shoes being too hard and not elastic, and many carbon fiber wastes and finished products on the market being unable to be recycled, the present invention proposes a method for manufacturing a recycled carbon fiber pad, wherein recycled carbon fiber materials are mixed with nylon or composite plastics to form a recycled carbon fiber injection material with elasticity, and the recycled carbon fiber injection material is injection-molded under an injection process condition to form a recycled carbon fiber pad. The present invention also proposes a recycled carbon fiber arch insole comprising a recycled carbon fiber pad layer manufactured by the aforementioned manufacturing method, and combines data from a big database of podiatry in ergonomics to conduct innovative design of mechanical insole products and development of recycled material applications. By using recycled carbon fiber materials to replace traditional plastic materials to manufacture recycled carbon fiber pad layers and recycled carbon fiber arch insoles comprising recycled carbon fiber pad layers, it is possible to effectively meet the environmental protection requirements of recycling and reducing carbon emissions by 80%, and increase the recycling usability of material recycling and regeneration.

Description

Recycled carbon fiber arch insole with recycled carbon fiber underlay

The present invention relates to the technical field of an arch insole for footwear, and more particularly to a regenerated carbon fiber arch insole with a regenerated carbon fiber padding layer.

When it comes to footwear, people generally put arch insoles in their shoes to reduce pressure and shock when walking or running to increase comfort. Especially in the post-epidemic era, everyone pays special attention to health, and the demand for medical or health-care mechanical arch functional insoles is also increasing.

Traditional arch insoles are mostly made of petrochemical plastic materials such as PP, PE plastic, pure carbon fiber, TPU and resin carbon fiber composites. They are difficult to manufacture and have no flexibility (for example, too hard, too thick), so they are less usable.

In addition, there are many types of arch insoles on the market, and most of them claim to have therapeutic functions, but none of them have actual ergonomics or medical mechanics design and actual medical verification. In addition, existing arch insoles generally have insufficient support for the medial arch, and the position and shape of the transverse arch insoles are incorrectly designed, which often causes people with relevant needs to waste money to try or be deceived.

In order to solve the various problems encountered by the above-mentioned traditional arch insoles, the present invention proposes a method for manufacturing a recycled carbon fiber insole layer, and the present invention also proposes a recycled carbon fiber arch insole, in which the recycled carbon fiber arch insole includes a recycled carbon fiber insole layer manufactured by the above-mentioned manufacturing method. The current recycling process calculates that 1 ton of recycled carbon fiber RCF will generate 4 to 4.5 tons of _CO2 emissions. Compared with the current public data of carbon fiber processes on the market, the production of 1 ton of carbon fiber CF will generate 20 tons of _CO2 emissions. The use of recycled carbon fiber materials can effectively reduce carbon emissions by nearly 80%.

The manufacturing method of the above-mentioned regenerated carbon fiber cushion layer includes the following steps: providing a regenerated carbon fiber material, the regenerated carbon fiber material has a first weight percentage; providing a nylon or a composite plastic, the nylon or the composite plastic has a second weight percentage, and the sum of the second weight percentage and the first weight percentage is 100%; mixing the regenerated carbon fiber material and the nylon or the composite plastic to form a regenerated carbon fiber injection material with elasticity; and injection molding the regenerated carbon fiber injection material into a regenerated carbon fiber cushion layer under an injection process condition.

In one embodiment without limitation, the first weight percentage is 50%, and the second weight percentage is 50%.

In one embodiment without limitation, the regenerated carbon fiber material is short fiber powder with a diameter of 0.1 mm to 0.5 mm.

In one embodiment without limitation, the nylon or composite plastic mentioned above is one of a PA6 grade nylon and a PA12 grade nylon.

In one embodiment, without limitation, the injection molding process conditions include a preset cooling time of 15 seconds.

In one embodiment without limitation, the injection molding process conditions include a preset screw speed of 88 rpm.

In one embodiment, without limitation, the above-mentioned injection process conditions include a preset injection time of 1.5 seconds.

The above-mentioned regenerated carbon fiber arch insole comprises a regenerated carbon fiber pad layer, and the regenerated carbon fiber pad layer is manufactured by the above-mentioned manufacturing method of the regenerated carbon fiber pad layer.

In one embodiment, the above-mentioned regenerated carbon fiber arch insole further comprises a first cushioning pad layer stacked on the regenerated carbon fiber pad layer.

In one embodiment, without limitation, the first buffer pad layer is defined as having a full foot length, and the length of the regenerated carbon fiber pad layer is three quarters of the full foot length.

In one embodiment, without limitation, the regenerated carbon fiber arch insole further comprises a graphene pad layer stacked on the first cushioning pad layer.

In one embodiment, without limitation, the length of the graphene pad is equal to the full foot length.

In one embodiment without limitation, the graphene mat is knitted from 92% graphene yarn and 8% elastic yarn.

In one embodiment, without limitation, the surface of the graphene pad is further printed with a honeycomb graphene material.

In one embodiment, the regenerated carbon fiber arch insole further comprises at least one second cushioning pad layer sandwiched between the regenerated carbon fiber pad layer and the first cushioning pad layer.

In one embodiment, the first buffer pad layer is a foam material, and the at least one second buffer pad layer is a rubber sheet.

In one embodiment, the regenerated carbon fiber mat has a specific profile, and the specific profile is determined by a plurality of corresponding profile statistics in a database.

Without limitation, in one embodiment, the above-mentioned multiple corresponding contour statistics include a corresponding contour statistic for the median length of the foot, a corresponding contour statistic for the medial length of the foot, a corresponding contour statistic for the lateral midfoot length of the foot, a corresponding contour statistic for the forefoot width of the foot, a corresponding contour statistic for the arch width of the foot, a corresponding contour statistic for the heel width of the foot, a corresponding contour statistic for the medial arch height of the foot, a corresponding contour statistic for the medial arch position of the foot, a corresponding contour statistic for the lateral arch height of the foot, and a corresponding contour statistic for the lateral arch position of the foot.

Without limitation, in one embodiment, the specific profile described above has an arch height and a width, the arch height includes a low arch height, a normal arch height and a high arch height, and the width includes a narrow width, a normal width and a wide width.

As described above, by using recycled carbon fiber materials to replace traditional plastic materials to manufacture recycled carbon fiber pads and recycled carbon fiber arch insoles containing recycled carbon fiber pads, the effect of recycling and recycling can be effectively achieved to meet environmental protection requirements, and the usability of recycled carbon fiber arch insoles can be increased due to the characteristics of the recycled carbon fiber materials themselves, such as light weight, high elasticity, fatigue resistance, easy manufacturing, high strength and toughness, and not easy to deform.

In addition, the contour of the recycled carbon fiber insole can be designed into a variety of different sizes based on different foot shapes using big data to meet different needs, and can also be customized to increase the variability of use. Furthermore, the health function of the far infrared rays of graphene materials can also make the recycled carbon fiber arch insoles have health effects.

In order to fully understand the purpose, features and effects of the present invention, the preferred specific embodiments of the present invention are described below with reference to the accompanying drawings.

Please refer to FIG. 1, which is an exploded view of a regenerated carbon fiber arch insole of a preferred embodiment of the present invention. FIG. 1 shows a regenerated carbon fiber arch insole 1 that can be placed in a shoe (not shown). The regenerated carbon fiber arch insole 1 mainly includes a regenerated carbon fiber pad layer 11 and a first cushioning pad layer 12. As shown in FIG. 1, in this embodiment, the regenerated carbon fiber arch insole 1 further includes a graphene pad layer 13 and two second cushioning pad layers 14, wherein: The first cushioning pad layer 12 is stacked on the regenerated carbon fiber cushion layer 11, the graphene cushion layer 13 is stacked on the first cushioning pad layer 12, and the two second cushioning pad layers 14 are respectively sandwiched between the regenerated carbon fiber cushion layer 11 and the first cushioning pad layer 12, and the two second cushioning pad layers 14 are arranged at the forefoot and the rearfoot corresponding to the sole of the foot, but avoiding the position of the midfoot (see also the foot shape definition in FIG. 3).

The first cushioning pad layer 12 is a foam material, and the second cushioning pad layer 14 is a rubber sheet, which can be used to reduce pressure and shock to improve the comfort of people using (stepping on) the recycled carbon fiber arch insole 1. Of course, the first cushioning pad layer 12 and the second cushioning pad layer 14 can also be designed in the opposite way, that is, the first cushioning pad layer 12 can be a rubber sheet, and the second cushioning pad layer 14 can be a foam material. In addition, the number of the second cushioning pad layer 14 is not limited to the two shown in FIG. 1 , and may be one, three, or other numbers. The shape, length, width, and height, and location of the second cushioning pad layer 14 may also be changed according to actual needs. For example, different designs may be made according to different arch heights, foot widths, and foot lengths.

The graphene pad layer 13 (also referred to as graphene surface cloth) mentioned above is knitted by mixing 92% graphene yarn and 8% elastic yarn in this embodiment, and a honeycomb graphene material 131 is further printed on the surface of the graphene pad layer 13, so that the content of graphene can be further increased. Graphene can have health benefits, such as helping blood circulation in the soles of the feet, increasing blood flow rate, etc. After verification and testing by a notarial unit, the graphene pad layer 13 designed in the above manner has a far-infrared emissivity of more than 0.83, and can achieve the effects of helping the limb temperature rise test to 13 ﾟC, increasing blood flow +11%, blood flow rate +12%, increasing finger blood oxygen concentration +1.0, and skin body temperature +0.9 ﾟC when using the recycled carbon fiber arch insole 1.

As mentioned above, the recycled carbon fiber arch insole 1 includes a recycled carbon fiber pad layer 11, that is, the pad layer is made of recycled carbon fiber materials instead of traditional plastic materials, thereby effectively achieving the effect of recycling and recycling to meet environmental protection requirements. In addition, the recycled carbon fiber material itself has many characteristics, such as light weight, thinness, high elasticity, fatigue resistance, easy manufacturing, high strength and toughness, and not easy to deform. Therefore, the pad layer is made of recycled carbon fiber material and used in the recycled carbon fiber arch insole 1, which can increase the usability of the recycled carbon fiber arch insole 1. The manufacturing method of the recycled carbon fiber pad layer 11 is described below.

Please refer to FIG. 2 , which is a flow chart of a method for manufacturing a regenerated carbon fiber pad layer of a preferred embodiment of the present invention. The flow chart shows the steps of the method for manufacturing the regenerated carbon fiber pad layer 11 included in the regenerated carbon fiber arch insole 1, and please refer to FIG. 1 together.

In the steps of the manufacturing method of the regenerated carbon fiber mat 11, first, a regenerated carbon fiber material is provided, and the regenerated carbon fiber material has a first weight percentage (step S01). In this embodiment, the first weight percentage of the regenerated carbon fiber material is 50%.

Next, a nylon or a composite plastic is provided, wherein the nylon or the composite plastic has a second weight percentage, and the sum of the second weight percentage of the nylon or the composite plastic and the first weight percentage of the recycled carbon fiber material is 100% (step S02).

Afterwards, the recycled carbon fiber material is mixed with nylon or composite plastic to form a recycled carbon fiber injection material with elasticity (step S03), which is the so-called mixing process. The recycled carbon fiber injection material contains 100% of the recycled carbon fiber material and nylon or composite plastic.

Then, the regenerated carbon fiber injection material is injection molded into a regenerated carbon fiber cushion layer 11 under an injection process condition, and the injection process condition includes at least one of a preset cooling time, a preset screw speed and a preset injection time (step S04).

In the above step S04, at least one of the various parameters included in the injection process conditions can be set according to the first weight percentage of the recycled carbon fiber material and the second weight percentage of the nylon or composite plastic. For example, the first weight percentage of the recycled carbon fiber material is 50%, the second weight percentage of the nylon or composite plastic is 50%, and the injection process conditions include a preset cooling time of 15 seconds, a preset screw speed of 88 rpm, and a preset injection time of 1.5 seconds.

The above-mentioned recycled carbon fiber material can be short fiber powder of 0.1mm to 0.5mm, such as 0.1mm, 0.2mm, 0.3mm, 0.4mm, 0.5mm, etc., and the nylon or composite plastic can be one of a PA6 grade nylon and a PA12 grade nylon, and of course other composite plastics can also be used. Similarly, the various parameters included in the above-mentioned injection process conditions can also be set according to the different types of the above-mentioned recycled carbon fiber material and nylon or composite plastic, so as to obtain, for example, a recycled carbon fiber pad 11 that meets the above-mentioned various test conditions.

Please refer to FIG. 1 again. As described above, the regenerated carbon fiber arch insole 1 comprises a regenerated carbon fiber pad layer 11, a second cushioning pad layer 14, a first cushioning pad layer 12 and a graphene pad layer 13 stacked on top of each other, wherein the first cushioning pad layer 12 defines a full foot length, i.e., the length of the entire foot plate from the heel to the toe, and the graphene pad The length of the layer 13 is equal to the full foot length, that is, the graphene pad layer 13 and the first buffer pad layer 12 have the same length. As shown in FIG. 1 , the graphene pad layer 13 and the first buffer pad layer 12 have the same outer profile. Of course, the graphene pad layer 13 and the first buffer pad layer 12 can also be designed to have different lengths and different outer profiles.

In addition, the length of the recycled carbon fiber pad layer 11 is three quarters of the length of the entire foot, including the range of the heel bone (hindfoot) and the midfoot bone (midfoot), that is, a three quarter arch insole skeleton design. In detail, the recycled carbon fiber pad layer 11 has a specific profile, and this specific profile depends on a plurality of corresponding profile statistics in a database, wherein the database is a database of people's foot types, which can be, for example, customer foot type data accumulated by general businesses after years of selling related arch insole products or related medical research units studying different foot types (such as low, The data base can also be further divided into data of foot types of different races. For example, the specific contour of the above-mentioned regenerated carbon fiber insole layer 11 can be determined by the (big) data base of the foot types of 37,500 Asian adults, which is accumulated by the industry through many years of sales of related arch insole products.

Please refer to Figures 3 and 4 at the same time, wherein Figure 3 is one of the example schematic diagrams of the foot type definition of a better specific example of the present invention, and Figure 4 is the second example schematic diagram of the foot type definition of a better specific example of the present invention. It should be noted that Figures 3 and 4 are only used for reference to show the definition of foot type in the field by way of example, and they are technical contents well known to those familiar with the technology in the field.

With reference to Figures 3 and 4, the above-mentioned multiple corresponding contour statistics include a corresponding contour statistic for the median length of the foot, a corresponding contour statistic for the medial length of the foot, a corresponding contour statistic for the lateral midfoot length of the foot, a corresponding contour statistic for the forefoot width of the foot, a corresponding contour statistic for the arch width of the foot, a corresponding contour statistic for the heel width of the foot, a corresponding contour statistic for the medial arch height of the foot, a corresponding contour statistic for the medial arch position of the foot, a corresponding contour statistic for the lateral arch height of the foot, and a corresponding contour statistic for the lateral arch position of the foot. Therefore, the specific contour of the three-quarter arch insole skeleton design of the recycled carbon fiber pad layer 11 can be designed based on the statistical values of the above-mentioned big data (i.e., the so-called ergonomics), and the recycled carbon fiber pad layer 11 manufactured in this way can conform to human body mechanics.

Please refer to FIG. 5, which is a schematic diagram of the profile change of the recycled carbon fiber pad layer of the preferred specific example of the present invention. As mentioned above, the specific profile of the recycled carbon fiber pad layer 11 can be designed into many different sizes according to different foot conditions using big data. For example, the specific profile has an arch height and a width, which can meet different needs and can be customized (for example, for daily activities, intense sports, correction and support, etc.), increasing the variability in use. For example, as shown in FIG5 , with the low, normal, and high arch heights displayed from left to right (i.e., low arch height, normal arch height, and high arch height), and each arch height design has narrow, normal, and wide sizes (i.e., narrow width, normal width, and wide width) in response to the numerous application requirements of current shoe types, the specific contour of the three-quarter arch insole skeleton design of the recycled carbon fiber pad layer 11 can be varied and designed according to the above-mentioned big data for the above-mentioned different conditions, so that many variable sizes can be obtained to meet different requirements.

The present invention has been disclosed in the above with a preferred specific embodiment, but those skilled in the art should understand that the preferred specific embodiment is only used to describe the present invention and should not be interpreted as limiting the scope of the present invention. It should be noted that all changes and substitutions equivalent to the preferred specific embodiment should be included in the scope of the present invention. Therefore, the protection scope of the present invention shall be based on the scope defined by the patent application.

1: Regenerated carbon fiber arch insole 11: Regenerated carbon fiber pad layer 12: First cushioning pad layer 13: Graphene pad layer 131: Honeycomb graphene material 14: Second cushioning pad layer S01: Step S02: Step S03: Step S04: Step

FIG. 1 is a disassembled diagram of a regenerated carbon fiber arch insole of a preferred embodiment of the present invention. FIG. 2 is a flow chart of a method for manufacturing a regenerated carbon fiber pad layer of a preferred embodiment of the present invention. FIG. 3 is one of the schematic diagrams of an example of foot shape definition of a preferred embodiment of the present invention. FIG. 4 is a second schematic diagram of an example of foot shape definition of a preferred embodiment of the present invention. FIG. 5 is a schematic diagram of contour changes of a regenerated carbon fiber pad layer of a preferred embodiment of the present invention.

1: Recycled carbon fiber arch insole

11: Recycled carbon fiber pad

12: First buffer pad layer

13: Graphene pad

131: Honeycomb graphene material

14: Second buffer pad layer

Claims (6)

A regenerated carbon fiber arch insole, comprising: a regenerated carbon fiber pad layer, which is made by injection molding under an injection process condition by mixing a regenerated carbon fiber material having a first weight percentage and a nylon or composite plastic having a second weight percentage to form an elastic regenerated carbon fiber injection material, wherein the sum of the first weight percentage and the second weight percentage is 100%; and a graphene pad layer, which is stacked on the regenerated carbon fiber pad layer, and a honeycomb graphene material is printed on the surface of the graphene pad layer. The regenerated carbon fiber arch insole as described in claim 1 further comprises a first cushioning pad layer stacked between the regenerated carbon fiber pad layer and the graphene pad layer. A regenerated carbon fiber arch insole as described in claim 2, wherein the first cushioning pad layer is defined as a full foot length, and the length of the regenerated carbon fiber insole layer is three quarters of the full foot length. The regenerated carbon fiber arch insole as described in claim 2 further comprises two second cushioning pad layers sandwiched between the regenerated carbon fiber pad layer and the first cushioning pad layer, and the two second cushioning pad layers are arranged at positions corresponding to the forefoot and the rearfoot of the sole but avoiding the midfoot. A regenerated carbon fiber arch insole as described in claim 1, wherein the regenerated carbon fiber insole layer has a specific profile, and the specific profile depends on a plurality of corresponding profile statistics in a data database, the plurality of corresponding profile statistics including a corresponding profile statistic for the median length of the foot, a corresponding profile statistic for the medial length of the foot, a corresponding profile statistic for the lateral midfoot length of the foot, a corresponding profile statistic for the forefoot width of the foot, a corresponding profile statistic for the arch width of the foot, a corresponding profile statistic for the heel width of the foot, a corresponding profile statistic for the medial arch height of the foot, a corresponding profile statistic for the medial arch position of the foot, a corresponding profile statistic for the lateral arch height of the foot, and a corresponding profile statistic for the lateral arch position of the foot. A regenerated carbon fiber arch insole as described in claim 5, wherein the specific profile has an arch height and a width, the arch height includes a low arch height, a normal arch height and a high arch height, and the width includes a narrow width, a normal width and a wide width.

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