Insole Shankboard Segmentation for Strobel Lasting
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Solution Overview
Problem
The existing methods for manufacturing safety shoe insoles with shankboards are incompatible with the Strobel lasting process due to the rigidity of shankboards, which prevents the use of standard production lines and increases costs due to the need for expensive piercing-resistant materials like Kevlar or Dyneema for full coverage.
Innovation Solution
A shankboard is arranged to extend radially over the insole surface and end about 5 mm from the periphery, allowing the insole to be stitched along its periphery, and a piercing-resistant member is attached to the underside where the shankboard ends, reducing material costs by only covering the necessary sections with expensive materials like Kevlar or Dyneema.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a shankboard is applied to the insole to provide stability and reduce the need for expensive piercing-resistant material, then manufacturing cost is reduced, but the insole cannot be stitched to the upper using the Strobel method due to the rigid shankboard extending along the full width
Solution Approach 1:
The insole is divided into two functional zones: a front foot section with piercing-resistant material for nail resistance, and a mid foot section with a shankboard for structural stability. This segmentation allows each zone to serve its specific purpose while enabling the Strobel lasting method to be applied to the front section where stitching is required.
Solution Approach 2:
Piercing-resistant material is applied locally only to the front foot section of the insole where nail penetration risk is highest, rather than covering the entire insole. This local application reduces material costs while maintaining safety performance, and allows the rigid shankboard to be installed in the mid foot section without interfering with the stitching process.
2Reliability
If expensive piercing-resistant material like Kevlar or Dyneema is used to cover the entire insole, then piercing resistance is ensured, but manufacturing cost increases significantly
Solution Approach 1:
Piercing-resistant material is applied locally only to the front foot section of the insole where nail penetration risk is highest, rather than covering the entire insole. This local application reduces material costs while maintaining safety performance.
Solution Approach 2:
Instead of providing full coverage with piercing-resistant material, the solution applies partial coverage only where absolutely necessary for safety performance. The shankboard provides structural support in the mid foot section, reducing the need for expensive material in that area.
3Stability of the object's composition
If the shankboard extends along the full width of the insole to provide maximum stability, then structural support is improved, but the insole cannot be stitched to the upper using standard Strobel lasting methods
Solution Approach 1:
The insole is divided into two functional zones: a front foot section with piercing-resistant material for nail resistance, and a mid foot section with a shankboard for structural stability. This segmentation allows each zone to serve its specific purpose while enabling the Strobel lasting method to be applied to the front section where stitching is required.
Solution Approach 2:
Instead of providing full coverage with piercing-resistant material, the solution applies partial coverage only where absolutely necessary for safety performance. The shankboard provides structural support in the mid foot section, reducing the need for expensive material in that area.
Data Source
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AI summary
The invention relates to an insole (20) to be used with a shoe (30), and a method of Strobel lasting a shoe (30). In an aspect of the invention, an insole (20) to be used with a shoe (30) is provided, the insole (20) comprising a shankboard (21) being attached to the insole (20), the shankboard (21) being arranged to partially extend over a surface of the insole (20) leaving a section (22) along a periphery (23) of the insole (20) free, thereby enabling Strobel lasting of the insole (20) to an upper (24) of the shoe (30).