Foam Insole With Impregnated Porous Insert
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Solution Overview
Problem
Existing methods for creating foam products with both soft and rigid portions require separate molding and gluing of materials, which is labor-intensive and prone to separation, and do not allow for controlled variation in rigidity or thickness.
Innovation Solution
A method involving a mold where a porous material is impregnated with foam during the molding process, allowing for the creation of a composite foam product with controlled rigidity by varying the thickness and density of the insert, eliminating the need for separate production and gluing of materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate molding and gluing of rigid and foam materials is used, then both rigid and soft portions can be created, but the process becomes labor-intensive and the components may separate
Solution Approach 1:
The patent merges the molding of rigid material and foam material into a single integrated process. The rigid material insert is placed within the mold cavity, and foam material is simultaneously molded around it, creating a unified composite product where the foam is directly bonded to the rigid insert without requiring separate gluing operations. This eliminates the labor-intensive assembly step and ensures reliable bonding through the intimate contact created during co-molding.
Solution Approach 2:
The rigid material insert is prepared in advance and placed in the mold cavity before the foam material is introduced. This preliminary positioning ensures proper alignment and contact between the rigid insert and the foam material before the molding process begins, facilitating direct bonding without requiring subsequent assembly operations.
2Adaptability or versatility
If multiple mold cavities are used to vary thickness, then thickness variation is achieved, but device complexity increases
Solution Approach 1:
The patent applies local quality by varying the thickness and placement of the rigid material insert in different regions of the mold cavity. By adjusting the insert's dimensions and position locally, the foam product achieves varying thickness and rigidity in specific areas without requiring multiple mold cavities or complex mold configurations. This allows customized thickness variation through simple insert design modifications.
3Reliability
If adhesive is used to attach rigid material to foam, then bonding is achieved, but additional materials and labor are required
Solution Approach 1:
The patent combines the rigid material insert and foam material into a single molded product, eliminating the need for adhesive materials. The direct contact between the insert and foam during the molding process creates inherent bonding without requiring additional substances. This reduces material quantity while maintaining bonding strength through the mechanical interlocking and intimate contact established during co-molding.
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
Enables the production of foam products with localized rigidity and varying thickness without the need for additional labor or adhesives, ensuring durability and comfort by integrating foam into porous materials during the molding process.
Implementation Method 1
The foamable material is allowed to cure while at the same time impregnating the porous material so as to render the porous material more rigid
Data Source
AI summary
A product, such as an insole (21, 22) or the like, is formed in a mold (20) having mold cavities (26, 27) therein. A porous insert (33, 34) is placed in the cavities (26, 27) and a foamable material (35) is introduced into the cavities (26, 27). When the material (35) cures, it impregnates the inserts (33, 34) which makes them more rigid. The resulting insoles (21, 22) thereby have a portion made up entirely of foam (35) and a portion made up of the insert material (33, 34) rigidified by the foam (35).