Vulcanised Rubber Boot Sole Insert for Lower Weight and Cushioning
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Solution Overview
Problem
Traditional vulcanised rubber footwear, particularly boots, are heavy and uncomfortable due to the solid nature of the sole member, which existing comfort-enhancing materials cannot withstand the vulcanisation process.
Innovation Solution
A method involving a sole member with a cavity and an insert comprising air pockets or channels, formed from thermoplastic materials like thermoplastic polyurethane, reduces weight and increases comfort by distributing compressive resistance evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid piece of rubber material is used to form the sole member, then the structural integrity and durability are improved, but the weight increases and comfort deteriorates
Solution Approach 1:
The sole member incorporates a foam material with a cellular structure containing numerous air pockets or voids distributed throughout the material. This porous structure reduces the weight of the sole member while maintaining adequate structural integrity through the distributed cellular framework, directly resolving the contradiction between weight reduction and structural strength.
Solution Approach 2:
The footwear combines rubber material with foam material in a composite construction, where the foam material serves as a lightweight core providing structural support, while rubber components provide durability and weather resistance. This composite approach allows the sole member to achieve both reduced weight and maintained structural integrity through synergistic material combination.
2Reliability
If a solid piece of rubber material is used to form the sole member, then the durability is improved, but the comfort deteriorates due to high compressive resistance
Solution Approach 1:
The foam material's cellular structure provides inherent cushioning properties by absorbing and distributing compressive forces through its air pockets. This reduces the overall compressive resistance of the sole member, enhancing comfort while the distributed cellular framework maintains durability through even stress distribution.
Solution Approach 2:
The invention changes the physical parameters of the sole member by introducing a foam material with controlled cell structure, altering the compressive resistance from high (solid rubber) to optimized levels. The foam's cell size, density, and distribution are controlled to achieve the desired balance between comfort (lower compressive resistance) and durability.
3Ease of operation
If traditional comfort materials are used in the sole member, then the comfort is improved, but the materials cannot survive the vulcanisation process
Solution Approach 1:
The foam material used is specifically selected to be heat-resistant and capable of withstanding the vulcanisation process temperatures. The cellular structure of the foam is stabilized through the vulcanisation process, which cures the rubber components and sets the foam structure, allowing the comfort material to survive the high-temperature curing process without degrading.
Solution Approach 2:
The composite construction combines heat-resistant foam material with rubber components that are vulcanised together. The foam material is positioned and secured within the footwear structure before vulcanisation, and the vulcanisation process bonds the rubber components while the foam maintains its structural integrity, creating a durable composite assembly that survives the curing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in a vulcanised rubber footwear with enhanced comfort and reduced weight by using a cushioning insert that maintains structural integrity during the vulcanisation process.
Implementation Method 1
The insert may comprise a plurality of air pockets or channels arranged within the insert. These act to reduce the compressive resistance of a material.
Implementation Method 2
The air pockets or channels may form a honeycomb structure. Regularly arranged air pockets or channels distribute the compressive resistance evenly across the insert.
Implementation Method 3
Vulcanisation is the process of curing elastomers and the terms vulcanisation and curing are sometimes used interchangeably.
Data Source
AI summary
The present invention relates to a method of forming an item of footwear and an item of footwear. In particular, the item of footwear is a boot formed of vulcanised rubber such as a Wellington boot. A method of forming an item of footwear comprising the steps of providing a sole member formed of a first rubber material having a first compressive resistance, the sole member comprising a cavity in an upper surface of a heel region of the sole member; placing an insert into the cavity, the insert having a second compressive resistance lower than the first compressive resistance; and then vulcanising to thereby attach an upper part formed of a second rubber material to the sole member at a first temperature, wherein the insert is formed of a material which is solid at the first temperature.