Flat Non-Trimmed Sole Bending for Mold-Free Shoe Assembly
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Solution Overview
Problem
Conventional shoe manufacturing methods require specific molds for each shoe shape, leading to increased complexity, material waste, and limited flexibility in design and comfort options.
Innovation Solution
A method involving a non-trimmed, flat sole with a processing burr or discard edge is bent to conform to the upper, eliminating the need for complex molds and allowing for unique designs and varied comfort levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional molds are used for each shoe shape, then the sole shape is precisely defined, but the device complexity and number of molds increase
Solution Approach 1:
A single universal mold is used to produce flat soles that can be adapted to multiple different upper shapes through bending and folding operations, eliminating the need for multiple specialized molds for different shoe types
Solution Approach 2:
The sole transitions from a static pre-shaped form to a dynamic form that can be bent and folded during assembly to conform to different upper shapes, allowing one mold design to serve multiple purposes
2Manufacturing precision
If conventional trimming is performed on soles, then the sole fits the upper precisely, but material waste increases
Solution Approach 1:
The excess material that would normally be trimmed and discarded is instead utilized through bending and folding operations to create functional and aesthetic features of the shoe sole, converting waste into value
Solution Approach 2:
Instead of discarding the excess sole material through trimming, the invention recovers and repurposes it by bending and folding to form the final sole structure that conforms to the upper
3Ease of manufacture
If pre-shaped soles are used, then the sole characteristics are defined before manufacturing, but design flexibility and comfort options are limited
Solution Approach 1:
The sole design transitions from fixed pre-shaped to dynamically adaptable through bending and folding operations, enabling the same base sole to achieve multiple final configurations for different design and comfort requirements
Solution Approach 2:
The sole is divided into functional zones (ground contact zone, upward extension zones) that can be independently positioned and shaped through bending and folding to optimize both manufacturing simplicity and design flexibility
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
Reduces material waste and manufacturing steps while enabling customizable shoe designs and enhanced comfort through the use of a non-trimmed sole that adapts to different upper shapes.
Implementation Method 1
bending the same on at least one upper
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
AI summary
Method for coupling a non-trimmed sole (4) and an upper (3) for making a shoe (1), which comprises the steps of providing a non-trimmed sole (4) having a flat and/or sheet-like shape and provided with a first surface (5), adapted during use to face towards the upper (3), wherein the non-trimmed sole (4) comprises a central part or impression (9) and an edge portion (11) which is extended outward starting from a peripheral portion of the impression (9), positioning the sole (4) in a position below the upper (3), moving the non-trimmed sole (4) so to enclose at least part of the upper (3), constraining the non-trimmed sole (4) and at least part of the upper (3) so as to obtain the shoe (1); shoe obtainable by means of such method.