Generic Injection Molded Shoe Frame for Multiple Footwear Styles
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Solution Overview
Problem
Existing footwear manufacturing methods require multiple molds for different shoe types, increasing production costs and complexity, whereas there is a need for a method to create various footwear styles from a single base platform efficiently.
Innovation Solution
The use of a generic injection molded base frame with a unitary midsole and upper portion, allowing different shoe types to be created by attaching distinct upper and outsole components, eliminating the need for conventional lasts and enabling cost-effective production of multiple footwear styles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple molds are used for different shoe types, then different footwear styles can be produced, but production costs and manufacturing complexity increase
Solution Approach 1:
The patent applies universality by creating a single generic base frame mold that can produce multiple different footwear styles (sneakers, backless shoes, skate shoes) by varying only the upper and outsole components attached to the same base frame, thereby eliminating the need for multiple specialized molds
Solution Approach 2:
The patent segments the footwear into a universal base frame component and variable upper/outsole components. The base frame serves as a standardized platform that can be combined with different upper portions and outsole elements to create various shoe types, separating the universal structure from the variable components
2Ease of manufacture
If conventional lasts are used, then traditional footwear manufacturing is maintained, but production efficiency and cost-effectiveness decrease
Solution Approach 1:
The patent replaces the traditional mechanical last system with an injection molding process. Instead of using physical lasts to form footwear shapes, the invention uses injection molding to directly form the base frame, eliminating the need for complex mechanical last systems and improving both simplicity and efficiency
3Reliability
If expensive materials like Gore-Text or Thinsulite are used, then durability and comfort are improved, but production costs increase
Solution Approach 1:
The patent changes the material parameter by using standard injection molding materials (such as thermoplastics or thermosets) instead of expensive specialized materials like Gore-Text or Thinsulite. By optimizing the molding process and base frame design, the invention achieves comparable durability and comfort at lower production costs
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 approach allows for the efficient production of various footwear styles, such as sneakers, backless shoes, and skate shoes, from a single base frame, reducing production costs and enabling customizable designs without the need for expensive materials like Gore-Text or Thinsulite, while maintaining durability and flexibility.
Implementation Method 1
forming a plurality of shoe frames by injecting molding a unitary, integral midsole and upper panel
Data Source
AI summary
Multiple shoe types are made from a plurality of generic molded base frames including a midsole and at least one upper portion integrally molded together. A first set of upper components is provided for forming a first shoe type secured to a first portion of the base frames and a second set of upper components is provided for forming a second shoe type secured to a second portion of the base frames. The upper portion that is integrally molded with the midsole may be a forefoot panel or a quarter. The various types formed from the generic frame include sneakers, backless shoes, slip-ons, skate shoes and boots. The generic unitary molded frame construction substantially reduces the cost of manufacture.