Core-Embedded Foamed Articles for Stronger Surface Bonding
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Solution Overview
Problem
Existing articles comprising a foamed member and a core lack structural improvements and efficient manufacturing methods that enhance bonding strength and coverage, particularly in applications like footwear components.
Innovation Solution
A method involving a molding process where a core is embedded in a foamed member, with the foamed member covering at least a portion of the core's surfaces, and a pattern is formed on the core's surfaces to enhance bonding, using a molding device with a supporting member and pressure-regulating system to control material injection and foaming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the core is partially exposed (at least an entire surface of the core exposed), then the manufacturing process is simpler, but the bonding strength and coverage are insufficient
Solution Approach 1:
The patent segments the core surface into different zones: a first surface that remains exposed for simplicity and a second surface that is fully covered by the foamed member for enhanced bonding. This segmentation allows different portions of the core to serve different functions - the exposed first surface facilitates manufacturing while the covered second surface provides superior bonding strength.
Solution Approach 2:
The foamed member is applied selectively to cover only the second surface of the core while leaving the first surface exposed. This local quality approach ensures that bonding enhancement is applied precisely where needed (on the second surface) without unnecessarily complicating the manufacturing process or exposing the entire core.
2Productivity
If the foamed member covers only part of the core, then the manufacturing process is simpler, but the coverage and structural integrity are insufficient
Solution Approach 1:
The patent divides the core into two distinct surfaces: a first surface that remains exposed to maintain manufacturing efficiency, and a second surface that is fully covered by the foamed member to ensure structural integrity. This segmentation allows the article to achieve both productivity and reliability.
Solution Approach 2:
The foamed member is strategically applied to cover the second surface of the core where structural integrity is most critical, while leaving the first surface exposed to maintain manufacturing efficiency. This localized coverage optimizes the balance between productivity and reliability.
3Strength
If adhesive is used to bond the foamed member and core, then the bonding strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent extracts the adhesive bonding step from the manufacturing process by designing the mold cavity to directly form the foamed member in contact with the core's second surface. This eliminates the need for separate adhesive application and bonding steps, reducing manufacturing complexity while maintaining bonding strength through direct foamed member coverage.
Solution Approach 2:
The mold cavity acts as an intermediary that directly forms the foamed member in the desired position and shape, eliminating the need for adhesive as a mediator. The mold cavity ensures proper contact and bonding between the foamed member and core during the foaming process itself, simplifying the overall manufacturing process.
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
Enhances bonding strength and coverage of the foamed member over the core, resulting in improved structural integrity and manufacturing efficiency for articles such as footwear components.
Implementation Method 1
injecting a first material into the mold cavity; and foaming the first material to form a first foamed member
Data Source
AI summary
An article includes a foamed member including a polymeric material, and a core embedded in the foamed member, the core includes a first surface, a second surface and a sidewall, the foamed member covers at least a portion of the first surface, and covers the entire sidewall and the entire second surface. A method of manufacturing an article includes providing a molding device including a first mold and a second mold, the first mold includes a supporting member protruded from an inner wall. The method further includes disposing a core on the supporting member; disposing the second mold over the first mold to form a mold cavity, the core is disposed within the mold cavity; injecting a first material into the mold cavity; and foaming the first material to form a first foamed member, wherein at least a portion of the first foamed member is in contact with the core.