Insert-Molded Lace Guides for Weldable Footwear Closure Attachment

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Solution Overview

Problem

Conventional closure systems for articles, such as footwear, are often expensive and complicated to manufacture, making it difficult for manufacturers to integrate reel-based mechanisms, leading to a need for simpler and more cost-effective coupling methods for tightening mechanisms.

Innovation Solution

The development of insert molded components with thermoplastic and thermoplastic elastomer materials for lace guides and tightening mechanisms that can be easily attached to articles, using methods like radio frequency welding and ultrasonic welding, to create customizable and adjustable lacing systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional reel-based closure systems are integrated into footwear, then the tightening function is achieved, but the manufacturing cost and complexity increase

Engineering Contradiction:

Improvetightening functionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The closure system is divided into separate functional components: a reel mechanism for tensioning, a lace guide for routing, and a footwear article. These components can be manufactured independently and then assembled, reducing the overall manufacturing complexity while maintaining the tightening function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reel-based tightening mechanism is extracted from the footwear manufacturing process and supplied as a separate component. This allows footwear manufacturers to focus on their core expertise while integrating proven tightening mechanisms from specialized manufacturers, thereby reducing manufacturing complexity and cost.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If reel-based tightening mechanisms are integrated into footwear, then the closure function is achieved, but the manufacturing cost increases

Engineering Contradiction:

Improveclosure functionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The reel-based tightening mechanism is designed as a universal component that can be integrated into various types of footwear and articles. This multi-functionality allows a single design to serve multiple applications, reducing development and tooling costs for manufacturers.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The closure system uses simple, easily manufactured components such as plastic lace guides and basic reel mechanisms that can be produced at low cost. These components are designed to be functional rather than premium, keeping manufacturing costs down while maintaining adequate performance.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Device complexity

If simple coupling methods are used for tightening mechanisms, then the manufacturing complexity is reduced, but the attachment reliability may be compromised

Engineering Contradiction:

Improvecoupling method complexityVSAvoidattachment reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The lace guide is pre-formed with attachment features (such as holes or tabs) during its manufacturing process. This preliminary preparation allows for simple subsequent attachment to the footwear using basic methods like stitching or adhesive, reducing both the complexity of the coupling method and ensuring reliable attachment.

Inventive Principle:

Principle #10Preliminary action

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 solution allows for the creation of cost-effective, customizable, and easily attachable lace guides and tightening mechanisms that enhance the fit and longevity of closure systems while reducing manufacturing complexity and costs.

Implementation Method 1

The insert molded component includes a housing member of a tightening mechanism that is made of a thermoplastic material having a first melting temperature... The flange member is made of a thermoplastic elastomer having a second melting temperature that is lower than the first melting temperature of the housing member.

Methodology Applied

Scientific EffectRadio frequency welding: Dielectric Heating

Implementation Method 2

using methods like radio frequency welding and ultrasonic welding, to create customizable and adjustable lacing systems

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS11253028B2Guides and components for closure systems and methods therefor

Publication Date: 2022.02.22 BOA TECHNOLOGY INC

AI summary

According to an embodiment, a component for attachment to an article includes an upper component that is made of a thermoplastic material having a first melting temperature and a flange member that is molded onto the upper component and made of a thermoplastic elastomer material having a second melting temperature that is lower than the first melting temperature of the upper component. The flange member extends laterally from a bottom end of the upper component so that a bottom surface of the flange member is flush with or positioned axially below a bottom surface of the upper component. The melting temperature of the thermoplastic elastomer material enables the flange member to be directly coupled to the article via heat welding and the like without substantially affecting the upper component.