Foam Particle Encapsulation in Additive Manufacturing

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Solution Overview

Problem

Traditional manufacturing methods for athletic equipment and footwear are limited in terms of customizability, speed, and flexibility, making it difficult to produce components with specific material properties and geometries, especially those requiring differential material properties across sub-regions.

Innovation Solution

The use of additive manufacturing methods incorporating foam particles dispersed in a liquid polymerizable composition, where each layer is polymerized and bonded to form a three-dimensional component with foam particles encapsulated by a polymeric material, allowing for the creation of components with varied material properties and geometries, such as midsoles, outsoles, and heel-cushioning pads.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional manufacturing methods are used, then production process is simple, but manufacturing time is long and customizability is limited

Engineering Contradiction:

Improvemanufacturing timeVSAvoidmanufacturing process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent changes the physical state of materials from solid to liquid polymerizable composition that can be precisely deposited and cured, enabling rapid manufacturing while maintaining process control through photopolymerization parameters

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials consisting of liquid polymerizable composition combined with foam particles, allowing the creation of components with tailored material properties such as flexural modulus, stiffness, and resilience through additive manufacturing

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If traditional manufacturing methods are used, then material properties are uniform, but ability to create differential material properties is poor

Engineering Contradiction:

Improvematerial property tailoringVSAvoidspatial control of material properties

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by dispersing foam particles non-uniformly within the liquid polymerizable composition, allowing different regions of the manufactured component to have different material properties such as density, stiffness, and resilience based on local foam particle concentration

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes material parameters by controlling foam particle size, distribution, and concentration in different regions, enabling spatial variation of material properties including flexural modulus and resilience within the same component

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If foam particles are incorporated in additive manufacturing, then components with tailored properties are achieved, but manufacturing process complexity increases

Engineering Contradiction:

Improvecustomizability of material propertiesVSAvoidadditive manufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical manufacturing processes with additive manufacturing using photopolymerization, where liquid polymerizable composition is deposited layer-by-layer and cured using light or other energy sources, enabling complex geometries and material property tailoring without complex mechanical tooling

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses composite materials of liquid polymerizable composition and foam particles that can be processed through additive manufacturing, combining the benefits of customizable material properties with the flexibility of additive manufacturing processes

Inventive Principle:

Principle #40Composite materials

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 approach significantly reduces manufacturing time by up to one-third while enabling the production of components with tailored properties, such as flexural modulus, stiffness, and resilience, enhancing performance and comfort in athletic footwear.

Implementation Method 1

polymerizing a first portion of the liquid polymerizable composition, forming a first layer including a first portion of a polymeric material which is the polymerized reaction product of the polymerizable composition

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS11617413B2Methods of manufacturing articles having foam particles

Publication Date: 2023.04.04 NIKE INC

AI summary

Methods for manufacturing three-dimensional components of articles, including articles of footwear, apparel, and sporting equipment are provided. The disclosed methods comprise providing a first composition comprising a plurality of foam particles suspended in a liquid polymerizable composition, polymerizing a first portion of the liquid polymerizable composition to form a first layer of polymeric material at least partially encapsulating a first portion of the plurality of foam particles, repeating the polymerizing and forming for at least a second and third iteration, each iteration forming a layer on the previous layer, thereby forming a three-dimensional component having at least three layers, each layer including foam particles at least partially encapsulated by the first polymeric material. Articles manufactured using the disclosed methods are also provided.