Expanded Material Particle Cushioning Element Molding
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Solution Overview
Problem
Existing manufacturing methods for cushioning elements in sports apparel require multiple steps and molds, limiting the control over characteristics and increasing production complexity.
Innovation Solution
A method involving loading a mold with randomly arranged particles of expanded material using a transport liquid or steam, followed by pressure and heat treatment to bond and shape the material, allowing for even distribution and influencing characteristics without additional adhesives, and using a heated mold surface to create structured surfaces for enhanced traction and stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple manufacturing steps and molds are used to produce cushioning elements, then the characteristics can be controlled, but the production complexity increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single integrated molding process. The mold system integrates particle loading, compression, heating, and bonding operations that were previously performed in separate steps, thereby reducing production complexity while maintaining control over cushioning element characteristics through unified process parameters.
Solution Approach 2:
The mold system is designed with multi-functionality to perform various operations simultaneously: loading expanded material particles, applying compressive force, heating to activate bonding, and shaping the cushioning element. This universal mold design eliminates the need for multiple specialized devices, reducing overall system complexity while preserving manufacturing precision.
2Manufacturing precision
If multiple manufacturing steps are used, then the characteristics can be controlled, but the number of manufacturing steps increases
Solution Approach 1:
The patent merges sequential manufacturing steps into a single integrated process where expanded material particles are loaded into the mold, compressed, heated, and bonded simultaneously. This consolidation reduces the total number of manufacturing steps from multiple separate operations to one continuous process, thereby improving productivity while maintaining characteristic control through integrated parameter management.
Solution Approach 2:
The integrated molding process enables continuous useful action by eliminating idle transitions between separate manufacturing steps. The process flows continuously from particle loading through compression, heating, and bonding in a single uninterrupted sequence, maximizing productivity while maintaining precise control over the cushioning element characteristics through sustained process parameters.
3Strength
If additional adhesives are used to bond material, then the bonding strength increases, but the manufacturing complexity increases
Solution Approach 1:
The expanded material particles are designed to bond with each other through self-service mechanisms activated by heat and pressure during molding. The material's inherent properties enable spontaneous bonding when subjected to the molding conditions, eliminating the need for external adhesives or additional bonding equipment, thereby maintaining bonding strength while reducing manufacturing complexity.
Solution Approach 2:
The bonding strength is achieved through parameter changes in the molding process rather than through additional materials. By controlling temperature, pressure, and time parameters during the molding operation, the expanded material particles are activated to bond strongly with each other, achieving the desired bonding strength through process parameters alone and avoiding the complexity of adhesive application systems.
4Strength
If the mold surface is heated to create structured surfaces, then the traction and stiffness improve, but the energy consumption increases
Solution Approach 1:
The mold surface heating is applied locally to specific zones where structured surfaces are required for enhanced traction and stiffness. Rather than heating the entire mold uniformly, only the regions needing surface structuring receive thermal energy, thereby achieving the desired mechanical properties while minimizing overall energy consumption through localized thermal treatment.
Solution Approach 2:
The heating of the mold surface utilizes thermal expansion principles to create the desired structured surface geometry. The localized thermal energy causes controlled expansion and deformation of the material in contact with the heated mold surface, forming the traction-enhancing structures. This approach achieves the mechanical property improvements through efficient thermal energy use rather than requiring additional high-energy processing steps.
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 method simplifies the manufacturing process, reduces the number of manufacturing steps, and allows for precise control over the characteristics of cushioning elements, enabling the production of lightweight, high-stability, and customizable shoe soles with improved traction and durability.
Implementation Method 1
loading a mold with randomly arranged particles of an expanded material, wherein the particles are loaded into the mold within a stream of a transport liquid and/or a stream of steam
Implementation Method 2
heating at least a part of the wall of the mold to a temperature which at least partially or entirely melts the particles of the expanded material that are adjacent to this part of the wall of the mold
Implementation Method 3
the particles of the expanded material are treated within the mold with pressure and/or heat and/or steam
Implementation Method 4
the particles of the expanded material are treated within the mold with pressure and/or heat and/or steam
Data Source
AI summary
Methods for manufacturing cushioning elements for sports apparel are described. A method is provided for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material. The method includes positioning a functional element within a mold and loading the mold with the particles of the expanded material, wherein the loading occurs through at least two openings within the mold and/or wherein the loading occurs between different movable parts of the mold.