Composite Shoe Outsole via Extrusion Embedding
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Solution Overview
Problem
Existing techniques for manufacturing shoe outsoles lack innovation in structure and production methods, with a need for improved characteristics and techniques to utilize natural materials effectively.
Innovation Solution
The use of composite sheet materials, created by embedding fabric or fibers into a base material through extrusion and subsequent processing, to fabricate shoe outsoles, allowing for mixed material contact surfaces and enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional injection molding or layer bonding techniques are used to make shoe outsoles, then production is simpler, but the ability to incorporate natural materials and achieve mixed material contact surfaces is limited
Solution Approach 1:
The patent applies composite materials by combining natural fabric or fiber materials with synthetic base materials (such as rubber or plastic) to create a unified outsole structure. The composite sheet material integrates both natural and synthetic components, allowing the outsole to meet the 50% natural material requirement while maintaining structural integrity and performance characteristics.
Solution Approach 2:
The patent segments the outsole manufacturing process into distinct functional layers: a base material layer providing structural support and a natural material layer (fabric or fibers) providing ground contact surface. This segmentation allows each material to perform its optimal function while being produced through an integrated extrusion process that combines multiple materials into a single composite sheet.
2Stability of the object's composition
If fabric or fibers are molded into the outsole using traditional techniques, then natural material content increases, but the integration and distribution of materials are less uniform
Solution Approach 1:
The patent merges the fabrication of the base material sheet and the embedding of fabric or fiber materials into a single integrated extrusion process. The extruder simultaneously processes the base material and natural fabric/fibers, combining them into a unified composite sheet material with uniform distribution, eliminating the need for separate molding or bonding steps.
Solution Approach 2:
The extrusion process acts as an intermediary mechanism that facilitates the uniform integration of natural fabric or fiber materials into the base material matrix. Through the extrusion die, both materials are forced to mix and distribute uniformly, creating a homogeneous composite structure that would be difficult to achieve through traditional layer-by-layer bonding or post-manufacturing embedding techniques.
3Quantity of substance
If multiple processing techniques are used to achieve 50% natural material content, then import duty rates improve, but the production time and process complexity increase
Solution Approach 1:
The patent implements continuous production by extruding the composite sheet material continuously through the extruder, rather than processing individual outsoles separately. The extrusion process runs continuously, producing a long composite sheet that is then cut to size, maintaining uninterrupted production flow and maximizing the efficiency of natural material incorporation throughout the entire production run.
Solution Approach 2:
The patent performs preliminary action by pre-mixing and pre-distributing the natural fabric or fiber materials with the base material during the extrusion process, before the material is cut and formed into individual outsoles. This preliminary integration ensures that each cut piece of outsole already contains the required 50% natural material content, eliminating the need for additional processing steps to verify or adjust natural material proportion.
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
This method enables the production of shoe outsoles with composite surfaces, combining synthetic and natural materials for improved durability and wear, while allowing for varied material distribution and enhanced performance characteristics.
Implementation Method 1
a sheet of composite material is produced by extruding a base material together with a sheet of fabric material
Implementation Method 2
embedding fabric or fibers into a base material through extrusion
Data Source
AI summary
Provided are, among other things, systems, methods and techniques for making a shoe outsole and to shoe outsoles made using such techniques. In one such technique, a sheet of composite material is produced by extruding a base material together with a sheet of fabric material. The sheet of composite material is then cut into an outsole component, and a shoe outsole is fabricated using the outsole component.