Thermoplastic Copolyester Foam Outsoles With Direct Thermal Bonding
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Solution Overview
Problem
Conventional rubber materials used in outsoles for footwear are difficult to recycle and require multiple manual processing steps for bonding, and they lack efficient adhesion to other materials, limiting sustainability and performance.
Innovation Solution
Thermoplastic copolyester foams with microcellular open-cell or closed-cell structures that can be directly molded onto other polymeric materials, providing secure bonding without adhesives and enabling easy recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rubber materials are used in outsoles, then durability and traction are achieved, but recyclability is poor and multiple manual processing steps are required for bonding
Solution Approach 1:
The patent changes the material parameter from conventional rubber to thermoplastic copolyester, which fundamentally alters the bonding mechanism from requiring adhesives and manual steps to enabling direct thermal bonding through melting and solidification cycles
Solution Approach 2:
The patent replaces the mechanical/adhesive bonding system with a thermal bonding system where the thermoplastic copolyester is melted and solidified to bond directly to other polymeric materials, eliminating the need for separate adhesive applications
2Reliability
If conventional rubber materials are used in outsoles, then traction is achieved, but adhesion to other materials is insufficient
Solution Approach 1:
The patent merges the outsole material and the bonding interface into a single thermoplastic copolyester material that provides both traction properties and adhesion capability through its thermal bonding mechanism, eliminating the need for separate adhesive layers
3Reliability
If conventional rubber materials are used, then traditional performance is maintained, but sustainability is limited due to difficulty in recycling
Solution Approach 1:
The patent enables the outsole material to be easily discarded and recovered through recycling processes by using thermoplastic copolyester that can be melted and reformed, allowing for circular economy implementation while maintaining performance
4Ease of manufacture
If thermoplastic copolyester foams are used, then recyclability and bonding ease are improved, but material strength may be reduced
Solution Approach 1:
The patent uses thermoplastic copolyester foam as a composite material that combines the structural properties of foam with the thermal bonding capabilities of thermoplastics, achieving both ease of manufacture and adequate strength for footwear applications
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 thermoplastic copolyester foams offer improved abrasion resistance, traction, and recyclability, with enhanced energy efficiency and reduced weight, making them suitable for athletic footwear components.
Implementation Method 1
a foam component comprising a foamed thermoplastic copolyester composition
Implementation Method 2
solidifying the foamed molten polymeric material, thereby forming a foam article having a microcellular foam structure
Data Source
AI summary
Components for articles of footwear and athletic equipment including a foam are provided. The foam portion of the components and articles include a composition which includes a thermoplastic copolyester, the composition having a foam structure. A polymer layer is provided on at least on surface of the foam portion. The polymer layer can control or reduce the water uptake of the foam portion. Methods of making the compositions, foams, and components are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding, or injection molding followed by compression molding.