Cork Overlay Outsole Molded with Textile Laminate
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Solution Overview
Problem
Existing footwear technologies struggle to effectively integrate a cork overlay with a tread pattern into an outsole without damaging the cork, while also ensuring a strong bond with a polymer layer.
Innovation Solution
A method involving a laminate of compressed natural cork with a woven textile backing, placed in a sole mold with protrusions for forming a tread pattern, and bonded with a polymer sheet under heat and pressure, allowing the cork to form around the protrusions and create a durable outsole with a tread pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cork layer is compressed between the mold surface and polymer sheet under heat and pressure, then the cork bonds with the polymer layer to form a durable outsole, but the cork may be damaged during compression
Solution Approach 1:
The mold surface is prepared in advance with protrusions that define the tread pattern. The cork layer is pre-positioned on the mold surface before polymer injection, ensuring proper alignment and preventing displacement during the bonding process. This preliminary arrangement allows the cork to be compressed uniformly without distortion or damage.
Solution Approach 2:
The compression process utilizes controlled changes in temperature and pressure parameters. Heat is applied to soften the polymer sheet, increasing its pliability and bonding capability, while pressure is applied uniformly through the mold to bond the cork to the polymer without exceeding the cork's structural tolerance. The parameters are optimized to achieve bonding without damaging the cork.
2Reliability
If protrusions are used on the mold surface to form tread pattern, then the outsole gains improved traction, but the protrusions may pass through the cork layer causing damage
Solution Approach 1:
The mold protrusions are designed with specific dimensional characteristics - their height and cross-sectional area are optimized to impart the tread pattern without penetrating through the cork layer. The protrusions contact only the surface of the cork, creating the desired tread pattern while leaving the cork layer intact and undamaged.
Solution Approach 2:
The cork layer thickness is predetermined and controlled during material preparation to ensure it is sufficient to withstand the compression force from the protrusions without perforation. The cork is pre-cut and positioned to cover the entire mold surface, ensuring uniform protection across all protrusion contact points.
3Reliability
If a laminate of cork with textile backing is used, then the cork maintains structural integrity during processing, but the manufacturing process becomes more complex
Solution Approach 1:
The cork layer is combined with a textile backing layer to form a laminate composite. The textile backing provides tensile strength and dimensional stability, preventing the cork from deforming or tearing during handling and compression. The composite structure allows the cork to maintain its natural properties while gaining enhanced processability.
Solution Approach 2:
The cork layer and textile backing are permanently bonded together in a factory setting to create a single integrated laminate. This merging eliminates the need for separate handling of cork and textile components during manufacturing, simplifying the overall process despite the initial complexity of creating the laminate. The combined structure is treated as one unit throughout the outsole fabrication process.
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 achieves a durable outsole with a tread pattern that provides improved traction and maintains the natural texture of the cork without damaging it, while ensuring a strong bond with the polymer layer.
Implementation Method 1
The laminate and polymer sheet are compressed between the first surface and a second surface of the sole mold in the presence of heat whereby the laminate is bonded with and overlays the polymer sheet
Implementation Method 2
The laminate and polymer sheet are compressed between the first surface and a second surface of the sole mold
Data Source
AI summary
A method of making footwear outsoles including providing a laminate including a cork layer and a textile layer, cutting the laminate into an overlay having a desired shape, placing the overlay into a sole mold with the cork layer arranged in direct contact with a first surface of the sole mold, the first surface including a plurality of protrusions configured for forming an outsole tread pattern, and placing a polymer sheet into the sole mold with the polymer sheet arranged adjacent to and in direct contact with the textile layer. The overlay and polymer sheet are compressed between the first surface and a second surface of the sole mold in the presence of heat whereby the laminate is bonded with and overlays the polymer sheet to form an outsole displaying at least a portion of the outsole tread pattern across the cork and polymer portions of the outsole.