Custom Inner Sole Board with Controlled Flex Zones
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Solution Overview
Problem
Existing footwear soles with varying flexibility characteristics fail to control the size and shape of co-molded materials, limiting the ability to customize flexibility for specific activities or individuals.
Innovation Solution
An inner sole board comprising two materials with different flexibility characteristics, bonded together in a molten state, where the size and location of one material are configured to conform to specific flexibility characteristics, using a single mold with controlled injection molding nozzles to establish dimensions and create a bonding zone for customized footwear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple materials are injected into a single mold to create varying flexibility characteristics, then customization of flexibility for specific activities is improved, but control of the size and shape of co-molded materials deteriorates
Solution Approach 1:
The injection molding process is segmented into multiple sequential stages, with each stage injecting a different material. The first material is injected and partially cured, then the second material is injected into remaining cavities. This segmentation allows precise control of each material's size and shape while achieving flexibility customization in different foot regions.
Solution Approach 2:
The first material is injected and allowed to partially cure or set before injecting the second material. This preliminary action establishes the size and shape of the first material portion, preventing it from flowing into regions designated for the second material, thereby maintaining manufacturing precision while enabling flexibility customization.
2Adaptability or versatility
If multiple materials are used in the sole, then flexibility characteristics can be varied for different regions, but the bonding between materials becomes difficult to control
Solution Approach 1:
The bonding between materials is achieved through phase transition - the first material is injected in a molten state, allowed to partially cool and set, then the second material is injected in its molten state and bonds to the first material at the interface. This phase transition approach ensures strong bonding while maintaining the flexibility variations needed for different foot regions.
Solution Approach 2:
The sole is constructed as a composite material structure with at least two different materials having different flexibility characteristics. The composite structure allows each material to be placed in specific regions of the foot (forefoot, midfoot, heel) to provide customized flexibility, while the bonding interface is controlled through the injection molding process to ensure structural integrity.
3Productivity
If a single mold is used for injection molding, then manufacturing efficiency is improved, but the ability to control dimensions of different materials deteriorates
Solution Approach 1:
The injection molding process is made dynamic by controlling the timing and sequence of material injection. The mold remains single and stationary, but the injection process dynamically adapts by injecting the first material, allowing it to partially cure, then injecting the second material into remaining cavities. This dynamic control maintains manufacturing efficiency while achieving precise dimensional control of each material portion.
Solution Approach 2:
The injection molding process uses periodic action by injecting materials in distinct time periods or stages. The first material is injected during one time period and allowed to partially cure, then the second material is injected during a subsequent time period. This periodic injection approach maintains high productivity with a single mold while precisely controlling the dimensions and positions of different materials in the sole.
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 solution allows for customizable footwear with varying flexibility regions, enhancing comfort and performance by providing a trampoline effect in the forefoot region while preventing over-flexing, thus reducing foot fatigue and injury risk.
Implementation Method 1
The bonding zone comprises a bond between the first material and the second material that is initiated when the first material and second material are in a molten state
Data Source
AI summary
An inner sole board having varying regions of flexibility is provided for use in an article of footwear. The inner sole board may include different materials along its length at different locations that vary its flexibility. An inner sole board is manufactured in an injection molding process requiring only one mold. The process includes a first step of providing a mold, a second step of providing an injection molding assembly, a third step of preparing an injection molding assembly and mold, a fourth step of injecting material into the mold, and a fifth step of establishing the dimensions of a first portion. During the injection molding process, the flow rate of at least one material may be controlled by a nozzle gate to control the shape and size of the flex zone it creates. In this manner, the inner sole board may be customized for a specific sport or individual.