Composite Sheet Sole Materials Using Patterned Extrusion
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Solution Overview
Problem
Existing materials for shoe soles face high manufacturing costs and poor environmental suitability, with challenges in minimizing import duties and carbon credits, particularly due to the high costs of raw materials and the unsatisfactory appearance of recycled materials.
Innovation Solution
The development of extrusion-based techniques for manufacturing composite sheet materials using a patterning template with openings, where the template and extrusion material can be made from different materials, including natural and recycled materials, to create a composite sheet with alternating surface areas, which reduces environmental impact and provides aesthetic benefits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If recycled materials are used for shoe soles, then manufacturing costs are reduced, but the appearance quality deteriorates
Solution Approach 1:
The patent combines recycled materials with natural materials (such as leather or fabric) in a composite construction where the recycled material forms the base layer and the natural material is bonded to the ground-contacting surface. This composite approach allows the product to benefit from the cost-effectiveness of recycled materials while maintaining the aesthetic and tactile qualities of natural materials on the visible and contact surfaces.
2Adaptability or versatility
If natural materials are used for shoe soles, then environmental suitability is improved, but manufacturing costs increase
Solution Approach 1:
The patent creates a multi-layer composite structure where natural materials are strategically placed on the ground-contacting portion to meet environmental certification requirements (such as FSC certification for at least 50% natural content), while recycled materials are used for non-contact portions. This composite construction achieves environmental suitability goals while reducing overall manufacturing costs compared to using natural materials throughout.
Solution Approach 2:
The patent applies natural materials specifically to the ground-contacting portion of the shoe sole where environmental interaction occurs, while using recycled materials for the upper and non-contact portions. This localized application of materials optimizes environmental suitability where it matters most while controlling manufacturing costs through selective material placement.
3Adaptability or versatility
If natural materials are used for shoe soles, then environmental suitability is improved, but slipping tendency increases
Solution Approach 1:
The patent combines natural materials with synthetic or recycled materials in a composite construction where each material contributes its advantageous properties. The natural material provides environmental suitability and comfort, while the synthetic or recycled material components provide enhanced friction and slip resistance, creating a balanced performance profile.
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 approach reduces manufacturing costs, enhances the suitability of shoe soles for various environments, and offers tax and import duty benefits by utilizing natural and recycled materials effectively, while mitigating the slipping tendencies of natural materials and improving the appearance of recycled materials.
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.