Self-Contained Footwear Molding Assembly with Integrated Hinge

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Solution Overview

Problem

Conventional processes for joining a bottom unit to a footwear upper are resource intensive, requiring multiple processing steps and large, complex machinery, leading to increased manufacturing costs and errors due to misalignment and wear on machinery components.

Innovation Solution

A compact molding assembly with a top mold member and base mold member, featuring a self-contained hinge mechanism that allows for rotation between open and closed configurations, reducing the need for oversized presses and minimizing the risk of manufacturing errors through precise alignment and reduced machinery footprint.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional large presses with interchangeable molding inserts are used, then versatility for different footwear sizes and styles is achieved, but device complexity and manufacturing cost increase significantly

Engineering Contradiction:

Improveversatility for different footwear sizes and stylesVSAvoidcomplexity of oversized molding system

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The molding assembly is designed as a self-contained unit that can be directly mounted to the footwear article, eliminating the need for a universal press system. The assembly integrates the molding insert with the mounting mechanism, allowing the same assembly to accommodate different footwear sizes and styles through design variations rather than requiring interchangeable inserts on a large press.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Force

If conventional large presses with distant hinge mechanisms are used, then sufficient force for opening and closing is achieved, but the machinery footprint and manufacturing space requirements increase

Engineering Contradiction:

Improveforce for opening and closing the moldVSAvoidmachinery footprint

Core Design Contradiction:

ForceVSArea of stationary object

Solution Approach 1:

The hinge mechanism is integrated directly into the molding assembly rather than being positioned at a distance on a large press frame. This merging of the hinge mechanism with the mold structure eliminates the need for oversized press machinery while maintaining sufficient closing force through the compact, self-contained design.

Inventive Principle:

Principle #5Merging (Combining)

3Force

If conventional oversized molding systems are used, then adequate molding force is achieved, but alignment precision and manufacturing reliability decrease due to wear and misalignment

Engineering Contradiction:

Improvemolding forceVSAvoidalignment precision of mold components

Core Design Contradiction:

ForceVSManufacturing precision

Solution Approach 1:

The molding system is segmented into self-contained molding assemblies that can be independently mounted to each footwear article. Each assembly maintains its own alignment and positioning, eliminating the cumulative misalignment issues that occur in large press systems where multiple components must be precisely aligned across a large workspace.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The molding assembly is designed to be self-aligning and self-contained, with the hinge mechanism and mold components working together as an integrated unit. This self-service design eliminates the need for external alignment mechanisms and reduces wear-related misalignment by keeping all moving parts in close proximity.

Inventive Principle:

Principle #25Self-service

4Ease of manufacture

If multiple processing steps and large machinery are used, then joining capability is achieved, but manufacturing cost and resource consumption increase

Engineering Contradiction:

Improvejoining capability of bottom unit to footwear upperVSAvoidresource intensity of manufacturing process

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The molding insert is pre-configured with the specific geometry and features required for the particular footwear article. This preliminary preparation allows the molding process to proceed in a single integrated step without requiring multiple separate operations for shaping, positioning, or securing the bottom unit to the footwear upper.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The molding assembly combines multiple functions (molding, positioning, and securing) into a single integrated unit that operates in one continuous process. This merging eliminates the need for separate processing steps and large machinery, reducing resource consumption while maintaining joining capability.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12005663B2Molding assembly and methods of using the same

Publication Date: 2024.06.11 NIKE INC

AI summary

A molding assembly having a top mold member and a base mold member. The top mold member can include a first top mold portion and a second top mold portion that shift between a top mold open configuration and a top mold closed configuration by rotating about a top mold hinge axis. The molding assembly can shift between a molding assembly open configuration and a molding assembly closed configuration by rotating at least the top mold member about a molding assembly hinge axis.