Insole Mold Process Eliminates Glue Adhesion
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Solution Overview
Problem
Existing insoles are poorly elastic, uncomfortable, and made from materials that emit odors and are difficult to degrade, often requiring glue for decoration which complicates the production process.
Innovation Solution
A production process for insoles that uses a mold to shape cloth and shoe material without adhesives, employing an oily release agent and specific chemical formulations to create a comfortable, durable, and environmentally friendly product with improved yield and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If cloth or leather of different colors and patterns is pasted on the insole using glues to make it beautiful, then the appearance is improved, but the device complexity and manufacturing process become more complex
Solution Approach 1:
The patent combines the decorative function and structural function into a single integrated insole layer. The cloth or leather with different colors and patterns is directly incorporated into the insole structure during the molding process, eliminating the need for separate gluing operations. This merging of functions resolves the contradiction by achieving beautiful appearance without complicating the manufacturing process.
Solution Approach 2:
The patent extracts the glue adhesion step from the manufacturing process entirely. By using a molding process that directly forms the insole with decorative surfaces, the harmful factor of glue application is removed, simplifying the device complexity while maintaining aesthetic appeal.
2Ease of manufacture
If traditional materials are used for insoles, then the manufacturing cost is low, but the insoles are poor in elasticity and not high in comfort
Solution Approach 1:
The patent employs composite materials that combine traditional low-cost materials with modern elastic materials. This allows the insole to maintain cost-effectiveness while achieving superior elasticity and comfort properties that traditional materials alone cannot provide.
Solution Approach 2:
The patent changes the physical and chemical parameters of the insole materials to improve elasticity and comfort. By adjusting material composition, density, and structural parameters, the insole achieves high comfort levels while maintaining manufacturing efficiency.
3Reliability
If the oily release agent is sprayed thickly to ensure proper release, then the release effect is improved, but the solvent cannot dry and the product surface becomes rotten
Solution Approach 1:
The patent optimizes the parameters of the oily release agent, including its composition, viscosity, and drying characteristics. By adjusting these parameters, the release agent can be applied at optimal thickness levels that ensure effective mold release while allowing the solvent to evaporate properly, preventing product surface defects.
Solution Approach 2:
The patent applies the release agent at controlled partial amounts rather than excessive thickness. This partial action approach ensures sufficient release effect while preventing the harmful consequence of trapped solvent that causes surface rotting.
4Manufacturing precision
If the cloth is forced into the nail position when hanging to ensure proper positioning, then the positioning accuracy is improved, but the quality of the product is affected and workers may be hurt
Solution Approach 1:
The patent incorporates preliminary positioning features directly into the mold design, such as pre-formed pockets, guides, or alignment structures. This preliminary action eliminates the need for forced positioning during assembly, achieving accurate cloth placement without compromising product quality or worker safety.
Solution Approach 2:
The patent introduces intermediary positioning elements or features that facilitate smooth cloth placement. These intermediaries act as mediators between the cloth and the final position, enabling accurate positioning without forceful insertion that could damage the product or injure workers.
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
The process results in insoles that are high in comfort, flexibility, and durability, with improved production efficiency, environmental sustainability, and resistance to water, acids, and solvents, while eliminating the need for glue and enhancing appearance.
Implementation Method 1
adjusting the spray gun into an atomizing shape when spraying the oily release agent with a spray gun, uniformly spraying a proper amount of oily release agent along the shape of the mold
Implementation Method 2
placing the mold in an oven for baking to emulsify and foam the shoe material
Implementation Method 3
baking to emulsify and foam the shoe material
Data Source
AI summary
A production process of an insole, the steps of: cleaning an insole mold; spraying an oily release agent into a cavity of an upper mold and a cavity of a lower mold of the mold; uniformly fixing cloth in the cavity of the upper mold; injecting shoe material into the cavity of the lower mold of the mold, covering the upper mold of the mold to lock the upper mold and the lower mold after finishing injecting shoe material, and then placing the mold in an oven for baking, opening the upper mold of the mold after finishing baking, and taking out the insole. The production process of an insole is simple in process and high in yield rate, and uses the characteristics that the cloth and the raw material have good adhesion to directly put the cloth into the mold to take shape, thereby eliminating a glue adhesion process.