Composite Sheet Extrusion with Patterned Fabric Reinforcement
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Solution Overview
Problem
Existing materials for shoe soles face challenges such as high manufacturing costs, high raw material costs, and poor suitability for specific environments, with additional considerations for minimizing import duties and carbon credits, particularly when using natural or recycled materials.
Innovation Solution
The development of extrusion-based techniques for manufacturing composite sheet materials, where a patterning template with openings is fed through an extrusion device with extrusion material, allowing for the creation of composite sheets with alternating areas of different materials, including natural and recycled materials, which can be embedded or replaced post-curing to achieve desired aesthetic and functional properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If natural materials are used in shoe soles, then import duties are reduced, but manufacturing cost and raw material cost increase
Solution Approach 1:
The patent combines natural fabric material with synthetic polymer material in a composite sheet structure. The natural fabric layer provides the required natural material content for reduced import duties, while the synthetic polymer matrix offers cost-effective manufacturing and desired performance properties. This merging allows simultaneous achievement of tax benefits and cost efficiency.
Solution Approach 2:
The invention creates a composite material system where natural fabric reinforcement is embedded in a synthetic polymer matrix. This composite structure enables the product to meet regulatory requirements for natural material content while leveraging the manufacturing advantages and cost benefits of synthetic materials, thereby resolving the contradiction between duty reduction and manufacturing cost.
2Object-affected harmful factors
If natural materials are used in shoe soles, then import duties are reduced, but material performance suitability for specific environments deteriorates
Solution Approach 1:
The patent merges natural fabric material with synthetic polymer material to create a composite sheet where each material contributes its strengths. The natural fabric provides structural reinforcement and meets import duty requirements, while the synthetic polymer matrix ensures reliability and suitability for specific environmental conditions through its inherent performance properties.
Solution Approach 2:
The invention applies different materials in different regions of the composite structure. The natural fabric is distributed throughout the matrix to provide localized reinforcement and meet natural material content requirements, while the synthetic polymer dominates the continuous phase to ensure overall reliability and environmental suitability. This local differentiation allows simultaneous achievement of tax benefits and performance reliability.
3Object-affected harmful factors
If recycled materials are used, then environmental impact is reduced, but manufacturing precision and material consistency worsen
Solution Approach 1:
The patent introduces a synthetic polymer matrix as an intermediary that encapsulates and binds recycled natural fabric material. This matrix acts as a mediating phase that distributes the recycled fibers uniformly throughout the composite structure, thereby improving material consistency and manufacturing precision while maintaining the environmental benefits of using recycled content.
Solution Approach 2:
The invention changes the physical and chemical parameters of the composite material system by combining recycled natural fabric with synthetic polymer. This parameter change transforms the variable properties of recycled materials into a consistent composite material with controlled characteristics, thereby achieving both environmental benefits and manufacturing precision through modification of the material system's fundamental parameters.
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 reduces environmental impact, mitigates material drawbacks like slipping tendencies, and provides tax and import duty benefits, while creating a composite sheet material that enhances aesthetic design and functional performance, such as in shoe outsoles.
Implementation Method 1
extrusion-based techniques for manufacturing composite sheet material
Data Source
AI summary
Provided are, among other things, systems, methods and techniques for manufacturing sheet material. In one representative embodiment, a sheet of fabric material is positioned across a patterning template that has a number of openings; and the sheet of fabric material and the patterning template are fed through an extrusion device in which extrusion material coats the fabric material and forces the fabric material into the openings in the patterning template, thereby producing a composite sheet material.