3D Thermo-Molding Footwear Upper Using Inflatable Bladder
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Solution Overview
Problem
Current footwear manufacturing methods fail to efficiently produce durable, lightweight, and customized footwear that balances durability, comfort, and cost-effectiveness while minimizing environmental impact.
Innovation Solution
A three-dimensional thermo-molding process using an inflatable bladder and a skin composed of low melting point thermoplastic polymers, where the skin is molded within a cavity to form a single integrally molded upper with defined forefoot, midfoot, and rearfoot portions, allowing for customized and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional footwear manufacturing methods are used, then production efficiency and cost-effectiveness are maintained, but durability, comfort, and customization capabilities are insufficient
Solution Approach 1:
The patent combines multiple footwear components (upper, midsole, outsole, lacing system) into a single integrated last assembly that is molded as one unified structure. This merging of components during the thermo-molding process eliminates the need for separate assembly steps, reducing manufacturing complexity while improving durability through integrated construction without seams or joints.
Solution Approach 2:
The patent utilizes composite material structures including the skin layer composed of thermoplastic polymer materials combined with textile or synthetic fibers. This composite approach enhances durability and comfort properties while maintaining manufacturability through the thermo-molding process that bonds these materials together in a single operation.
2Adaptability or versatility
If customized footwear is produced to improve comfort, then individual fit and comfort are enhanced, but manufacturing cost and complexity increase
Solution Approach 1:
The patent segments the footwear design into customizable parameters (last shape, skin thickness, material selection, reinforcement zones) that can be independently adjusted for different foot types and comfort requirements. This segmentation allows customization without requiring completely different manufacturing processes, as each parameter can be modified within the existing thermo-molding framework.
Solution Approach 2:
The patent enables customization by changing physical parameters of the molding process including temperature, pressure, and mold cavity dimensions. These parameter adjustments allow the same basic manufacturing process to produce varied customized footwear at low cost, as the thermo-molding process is inherently flexible to parameter changes without requiring new tooling or assembly procedures.
3Productivity
If higher processing temperatures are used to improve molding efficiency, then production speed increases, but volatile substance release and chemical reactions increase
Solution Approach 1:
The patent optimizes the processing temperature parameter to a specific range that is sufficient to melt and form the thermoplastic polymer materials but remains below the threshold that causes excessive volatile substance release or unwanted chemical reactions. This precise parameter control maintains productivity while minimizing harmful emissions.
Solution Approach 2:
The patent utilizes the controlled thermal properties of the thermoplastic polymer materials, which soften and become moldable at specific temperature ranges. By precisely controlling the heating process to match the material's thermal characteristics, the process converts thermal energy into beneficial material flow and bonding while avoiding temperatures that would cause degradation or excessive emissions.
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 method enables the production of customized footwear with improved durability and comfort while reducing manufacturing costs and environmental impact by using low melting point thermoplastic polymers and controlling processing temperatures to minimize volatile substance release and chemical reactions.
Implementation Method 1
The skin is pressed against an interior surface of the heated mold cavity to cause the skin to take on the shape of the internal surface of the mold cavity
Implementation Method 2
heating the mold to a predetermined temperature; and inflating the inflatable bladder such that the skin is pressed against an interior surface of the heated mold cavity
Data Source
AI summary
Methods for manufacturing uppers for articles footwear that include thermo-forming an upper composed of one or more low melting point thermoplastic polymers. The methods may include disposing a skin for forming an upper over and inflatable bladder. The skin may include at least one of a base layer composed of a low melting point thermoplastic polymer and a grid layer including a yarn composed of a low melting point thermoplastic polymer. The skin and inflatable bladder may be placed into a mold cavity and the mold may be heated to a predetermined temperature. The inflatable bladder may be inflated such that the skin is pressed against an interior surface of the heated mold cavity to cause the skin to take on the shape of the internal surface of the mold cavity, thereby forming an upper for an article of footwear.