Footwear Bladder Molding Process for Sole Assembly

Solution Overview

Problem

Conventional footwear with bladders are expensive and complicated to manufacture due to the separate production of the bladder, which increases part costs and manufacturing complexity.

Innovation Solution

A method of manufacturing footwear that involves molding multiple layers simultaneously, including a top layer, outsole layer, and bladder layers, to form the upper, footbed, and outsole, with the bladder layers defining a chamber to contain fluid, thereby integrating the bladder into the sole assembly efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the bladder is manufactured separately and then assembled into the sole assembly, then the bladder can be produced with precise control over its structure and fluid containment, but the manufacturing complexity and part costs increase significantly

Engineering Contradiction:

Improvebladder structure controlVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges the bladder manufacturing process with the sole assembly molding process by providing multiple layers (including bladder layers with fluid-containing chambers) that are molded together substantially simultaneously. This integration eliminates the need for separate bladder production and assembly steps, resolving the contradiction by combining what were previously separate operations into a unified manufacturing process that maintains bladder structural integrity while reducing overall complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The molding apparatus is designed to perform multiple functions simultaneously: it molds the upper, footbed, outsole, and bladder chambers in a single operation. The process universally handles both structural components and fluid-containing bladder components, eliminating the need for specialized separate manufacturing lines and reducing manufacturing complexity while maintaining precision

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If the bladder is manufactured separately and then assembled into the sole assembly, then the bladder can be produced with precise control over its structure and fluid containment, but the manufacturing costs increase due to increased part count

Engineering Contradiction:

Improvebladder structure controlVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent merges the bladder manufacturing process with the sole assembly molding process by providing multiple layers (including bladder layers with fluid-containing chambers) that are molded together substantially simultaneously. This integration eliminates the need for separate bladder production and assembly steps, resolving the contradiction by combining what were previously separate operations into a unified manufacturing process that maintains bladder structural integrity while reducing overall complexity

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If multiple layers are molded together substantially simultaneously, then the manufacturing process is simplified and costs are reduced, but the integration of the bladder into the sole assembly must be achieved without compromising structural integrity

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidbladder integration integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent merges the bladder manufacturing process with the sole assembly molding process by providing multiple layers (including bladder layers with fluid-containing chambers) that are molded together substantially simultaneously. This integration eliminates the need for separate bladder production and assembly steps, resolving the contradiction by combining what were previously separate operations into a unified manufacturing process that maintains bladder structural integrity while reducing overall complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs composite layering where bladder layers (containing fluid chambers) are integrated with structural layers (upper, footbed, outsole) in a single molded construction. This composite approach ensures that the bladder and sole assembly become a unified structure with reliable integration, as the layers are bonded together during the molding process rather than being assembled separately, thereby maintaining both productivity and reliability

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS9681700B2Article of footwear with bladder and method of manufacturing the same

Publication Date: 2017.06.20 NIKE INC

AI summary

A method of manufacturing an article of footwear having an upper, a footbed, an outsole, and a bladder that is disposed between the footbed and the outsole includes providing a plurality of layers. The layers include a top, outsole, first bladder, and second bladder layer. Also, the method includes molding the layers together substantially simultaneously to form the upper, the footbed, the outsole, and the bladder.