Foamed Polymeric Boot Shell with Adhesive-Bonded Sock Liner
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Solution Overview
Problem
Current work and recreation boots face challenges in being both sturdy and comfortable while providing water resistance, as traditional rubber shells are heavy and labor-intensive to manufacture, and lack effective insulation and chemical resistance.
Innovation Solution
The use of a foamed polymeric shell, such as ethylene vinyl acetate (EVA), combined with a foamed sock liner and an adhesive layer, where the sock liner's enclosed section does not intermingle with the shell's inner surface, forming a lightweight, insulating, and water-resistant boot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rubber shells are used, then water resistance and sturdiness are improved, but weight and manufacturing complexity increase
Solution Approach 1:
The patent uses foamed polymeric materials with closed-cell structures that provide water resistance through their cellular architecture. The foam material contains trapped gas pockets that prevent water penetration while significantly reducing density compared to solid rubber, achieving both water resistance and weight reduction simultaneously.
Solution Approach 2:
The patent combines foamed polymeric materials with adhesive layers to create a composite boot structure. The shell is formed by bonding foam material to a sock liner using adhesives, creating a composite construction that maintains water resistance while reducing overall weight and simplifying manufacturing compared to traditional solid rubber boots.
2Reliability
If traditional rubber shells are used, then protection is improved, but manufacturing labor intensity increases
Solution Approach 1:
The patent divides the boot into separate components: a foamed polymeric shell, a sock liner, and adhesive layers. These segments are manufactured separately and then assembled through bonding processes, which simplifies manufacturing compared to forming traditional solid rubber boots in single pieces, reducing labor intensity while maintaining protective properties.
Solution Approach 2:
The patent changes the physical state of the polymeric material from solid rubber to foamed structure, and changes the manufacturing process from molding solid pieces to assembling bonded components. This parameter change in material structure and fabrication method reduces manufacturing complexity and labor requirements while preserving protective functionality.
3Weight of moving object
If foamed polymeric materials are used, then weight and comfort are improved, but structural density is reduced
Solution Approach 1:
The patent utilizes foamed polymeric materials with closed-cell structures that provide sufficient structural strength despite reduced density. The cellular architecture of the foam maintains integrity and protective properties while achieving the desired weight reduction and comfort characteristics.
Solution Approach 2:
The patent creates a composite structure by bonding foamed material to a sock liner with adhesive layers. This composite construction compensates for the reduced structural density of the foam alone, maintaining overall boot strength and durability while preserving the weight and comfort benefits of the foamed material.
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
The solution results in boots that are sturdy, comfortable, thermally insulative, and provide excellent liquid and water resistance, with reduced weight and enhanced chemical resistance, improving manufacturing efficiency and wearability.
Implementation Method 1
an adhesive layer affixing an inner surface of the shell and a second surface of the enclosed section of the sock liner
Implementation Method 2
The boots herein are advantageous over prior art boots using unfoamed shells in that the lighter-weight foamed polymer material reduces overall weight of the boot while providing excellent chemical and water resistance and insulating properties
Implementation Method 3
The shells of such boots are made of traditional rubbers and polymers that are not foamed and have densities in excess of 1.0 gm/cc. The lighter-weight foamed polymer material reduces overall weight of the boot
Implementation Method 4
providing excellent chemical and water resistance
Data Source
AI summary
A boot comprises: a shell comprising a first foamed polymeric material; a sock liner comprising a second foamed polymeric material, the sock liner having an exposed section and an enclosed section; and an adhesive layer affixing the shell and the enclosed section of the sock liner; wherein there is an absence of intermingling of the second surface of the enclosed section of the sock liner with the inner surface of the shell. Methods of making and using the boot are also provided.