Cork Composite Footwear Midsole Microwave Bonding
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Solution Overview
Problem
Existing cork composites for footwear midsoles face challenges such as inconsistency in bonding, high energy consumption, and long cycle times, resulting in products that are either too fragile or lack desirable mechanical properties like density and cushioning control.
Innovation Solution
A method involving the use of cork particles combined with a binder material, where the mixture is subjected to electromagnetic radiation, such as microwave energy, to fuse the cork particles with the binder, forming a stable and homogenous cork composite material with improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing binding agents are used to bond cork particles, then the composite material can be formed, but the mechanical properties are limited and the product becomes either too fragile or too rigid
Solution Approach 1:
The patent applies parameter changes by controlling the moisture content of cork particles (10-50% dry basis), the ratio of binder to cork (1:9 to 4:6 by weight), and processing temperature (100-200°C) to achieve desired density and cushioning properties while maintaining good mechanical strength
Solution Approach 2:
The patent uses composite materials by combining cork particles with natural or synthetic binders (such as starch, lignin, or polyethylene glycol) to create a material that exhibits both the desirable mechanical properties of cork and the bonding capabilities of the binder, achieving a balance between strength and adaptability
2Productivity
If traditional manufacturing methods are used for cork composites, then the material can be produced, but energy consumption is high and cycle time is long
Solution Approach 1:
The patent replaces traditional mechanical compression and high-temperature curing methods with a combination of moisture-controlled compression and lower temperature processing (100-200°C), significantly reducing energy consumption while maintaining production efficiency
Solution Approach 2:
The patent applies preliminary action by pre-moistening cork particles to optimal moisture content (10-50% dry basis) before compression, which facilitates better bonding during the compression process itself, eliminating the need for separate high-energy curing steps and reducing overall cycle time
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 reduces energy consumption and cycle time while producing a cork composite material with enhanced bonding, density control, and cushioning properties, making it suitable for footwear applications.
Implementation Method 1
a binder material is added to a plurality of cork particles to form a mixture
Implementation Method 2
applying energy to the mixture, wherein the energy applied to the mixture includes electromagnetic waves
Implementation Method 3
applying energy to the mixture, where the energy includes microwave radiation and applying energy to the mixture fuses the cork particles with the binder material
Implementation Method 4
cooling the mixture, wherein cooling the mixture solidifies the mixture, thereby forming the cork composite material
Data Source
AI summary
A method of fabricating a cork composite material is disclosed herein. The method includes providing a plurality of cork particles, adding a binder material to the cork particles to form a mixture of the cork particles and the binder material, transferring the mixture to a mold, applying energy to the mixture, cooling the mixture, and removing the cork composite material from the mold. Further, the energy includes electromagnetic radiation that fuses the cork particles with the binder material. Cooling the mixture solidifies the mixture, thereby forming a cork composite material.